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ML-TRIM User Manual (806KB PDF)

1. 3 3 Keypad Lockout ite Eike 3 5 Control Parameters an aede tret P c 3 7 Direct MOG iiie io vU KA Ead ODE 3 8 Master Mode ite e erbe Ee eben Pets 3 9 Follower 3 13 Inverse Master 3 22 Inverse Follower 3 24 Acceleration Deceleration 3 26 TTE 3 27 TITO UEM 3 29 Soo 3 31 an en ai el 3 33 EOQIGIIMPUTS eL ind 3 34 Logic OUIDUL icon 3 37 Monitor Parameters cereo ib iia 3 39 Input 3 40 Output Monitoring desirte at EE 3 42 Performance Monitoring 3 43 Status Monitoring 00010 rca e E naas 3 45 Serial 3 49 Using Serial 3 50 Communications Software 3 52 Troubleshooting 4 1 uut ed 4 3 Troubleshooting ec tt inn 4 11 PROM chip Replacement 4 16 GOSS APY Glossary 1 GIOSS ii a ee ed ee Gloss
2. pue esp ul JON esp ul 10N 2101 julodjes 04 001 4 UBIH dolS H 1013 pajeos 1103207 JO ON jnoeui nu3 103201 JO qno w L ON ON anen ON any spol Spo 04 SPON annoy epo JOISEN 0 epo Aue UO 3 67 68 NOTES Troubleshooting Diagnostics Troubleshooting PROM Chip Replacement DIAGNOSTICS This section describes how to use the diagnostic routines to verify that the ML Trim is operating properly as well as to identify any ML Trim problems The diagnostic routines are run independently with the ML Trim temporarily disconnected from your system Begin diagnostics with the Clear 4 procedure then run tests 1 6 Each of the tests can be performed without repeating the Clear 4 procedure unless you exit diagnostics If you need to verify the integrity of the ML Trim relative to your system refer to the Troubleshooting Troubleshooting section page 4 11 If the information in this section does not solve your problem consult Contrex Technical Support 763 424 7800 or 1 800 342 4411 Gleaci4 Te Beein the Di en To begin the diagnostic procedure turn the
3. off and disconnect it from your system Turn the power on the ML Trim while simultaneously pressing Clear and 4 on the keypad The ML Trim defaults to RAM Test 1 The Diagnostic indicator and the number 1 are visible on the left side of the LED display If you did not see this indicator you are not in diagnostics The example below shows the diagnostic indicator and test number on the LED display Test Number RAM Test 1 To Test Random Access Memory Clear 4 will automatically default to RAM Test 1 The diagnostic indicator and the number 1 will be visible on the left side of the LED display To enter this test from another diagnostic test press the UP or DOWN scroll keys until the number 1 is visible in the left side of the LED display Press Enter to start the test If RAM fails 5 is displayed The test will stop if a failure is detected Press Clear to exit the test IF the RAM is good the ML Trim will display 0 0 0 0 Press Clear to exit the test Press CODE SELECT only if you want to exit diagnostics Display Test 2 To Test the LED Display Panel Segments Press the UP or DOWN scroll keys until the diagnostic indicator and the number 2 are visible on the left side of the LED display Press Enter to start the test The ML Trim will quickly run through all of the display variations Watch each of the display variations carefully for missing segments
4. MP 41 Lead Frequency MP 53 Control State MP 43 Feedback Frequency MP 54 Logic Inputs GroupA MP 44 Deviation MP 55 Logic Inputs GroupB EA MP 45 Scaled Reference MP 56 LogicOutputs MP 46 RampedReference 57 EEPROMStatus 47 Command Output MP 58 Serial Comm Error MP 48 TrimOutput MP 59 FrequencyOverflow_ MP 50 Active Scaling Mode MP 99 Software Code Rev MP 51 Keypad Error MP 00 Software APPENDIX G WIRING DIAGRAM EXAMPLES DANGER This diagram is for conceptual purposes only Use safety equipment Make wiring connections carefully Incorrect use of equipment or connections can cause injury or death 115vac A 0 1 AMPS 50 60 HZ MST FOL SETPT COM 588 om me COM AUX 20 SUL 5V Ext ma E COM Pwr Supply DOE LEAD_FQ gt zEm FDBK FQ Feedback 85 24 Freq MAX_SPD ES 3 2 zi lt RUN Run Speed DRV_SIG a se im Jo ae DRV_COM Pm COM i J2 2 R STOP R Stop sa F STOP AC POWER COM F Stop DN mm O lige X L1 DRV EN ALARM DIGITAL OUTPUTS COM Figure G 1 ML Trim Wiring Connections without Relays DANGER This diagram is for conceptual purposes only Use safety equipment Make wiring connections carefully Incorrect use of equipment or connections can cause injury or
5. vii viii Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 3 5 Table 3 6 Table 3 7 Table 3 8 Table 3 9 Table 3 10 Table 3 11 Table 3 12 Table 3 13 Table 3 14 Table 3 15 Table 3 16 Table 3 17 Table 3 18 Table 3 19 Table 3 20 Table 3 21 Table 3 22 Table 3 23 Table 3 24 Table 3 25 Table 3 26 Table 3 27 Table 3 28 Table 3 29 Table 3 30 Table 3 31 Table 3 32 Table 3 33 Table 3 34 Table 3 35 Table 3 36 List of Tables Basic Keypad Entry 3 4 Default Direct Mode Control Parameters 3 8 Entering Direct Mode Control Parameters 3 8 Default Master Scaling Control Parameters 3 10 Entering Master Scaling Control Parameters 3 10 Entering Master Setpoint Control Parameters 3 11 Master Mode Control Parameters Example 3 12 Default Follower Scaling Control Parameters 3 14 Entering Follower Scaling Control Parameters 3 14 Entering Follower Setpoint Control Parameters 3 15 Follower Mode Control Parameters Example A 3 18 Follower Mode Control Parameters Example B 3 21 Default Inverse Master Control Parameters 3 22 Entering Inverse Master Control Parameters 3 22 Inverse Master Mode Con
6. 1 Ip H3MOd ov Figure G 5 Two Channel Start Stop Lead Follower Logic DIGITAL INPUTS DIGITAL OUTPUTS DIGITAL OUTPUTS 3 5V COM_AUX 5V DI COM LEAD FQ FDBK FQ COM RUN JoG COM R STOP F STOP COM MST FOL SETPT COM V DO EN ALARM COM 3 3 5V COM_AUX 5V DI COM LEAD FQ FDBK FQ COM RUN JOG COM R STOP F STOP COM MST FOL SETPT COM V DO EN ALARM COM 5VExt Pwr Supply Feedback Frequency Run Jog R Stop F Stop Setpoint Select Lead Frequency Feedback Frequency Run Jog R Stop F Stop Master Follower Setpoint Select NOTES REVISION LOG APPENDIX H Jenueui ay jo uosa jueJuno JSOW y eui esn eJeu si jeuw UCU juega si uoisi eJ y jou SUOS SuonoeJoo pue sejepdn inox907 86 40 Bulpnjoul aoue duo 39 suomnoeuo9 pue sayepdn ISIN pue sejepdn as yy pue sejepdn as yy eseejeu sabed 00 6 1899 e za gt as Ex A9H ojeq JequinN UOISIASY uoisi eH 093 enuen H 1 NOTES Warranty Service Policy
7. CP 16 controls the rate of speed change in response to setpoint changes This Control Parameter applies to both the Master and Follower modes of operation Enter the desired number of seconds to increase the motor speed from 0 to 2000 RPMs CP 17 DECELERATION TIME Deceleration Time CP 17 controls the rate of speed change in response to setpoint changes This Control Parameter applies to both the Master and Follower modes of operation Enter the desired number of seconds to decrease the setpoint in the range of 2000 to 0 RPMs CP 20 MASTER ENGINEERING UNITS The actual value of the Master Engineering Units CP 20 if the system were to operate at the desired maximum RPMs refer to CP 34 This is not to be confused with the setpoint which is the Master Engineering Units at which you want the system to operate CP 21 FOLLOWER ENGINEERING UNITS In Follower Engineering Units CP 21 enter a number that will represent the setpoint Engineering Units when the Lead and Follower are operating at the maximum desired RPM This number is usually the ratio of Max RPM Feedback CP 34 to Max RPM Lead CP 33 When this number is also entered as a setpoint CP 03 or CP 04 the Follower will operate at Max RPM Feedback CP 34 when the Lead is at Max RPM Lead CP 33 CP 30 PPRLEAD PPR Lead CP 30 is the number of gear teeth or number of encoder lines on the Lead sensor per revolution pulses per revolution CP 31 PPR FEEDBACK PPR Feedback C
8. For example a nine with missing segments could look like a seven The ML Trim will display the following 00 0000 0 0 0 0 0 0 11 1111 1 1 1 1 1 1 22 2222 2 2 2 2 2 2 33 3333 3 3 3 3 3 3 44 4444 4 4 4 4 4 4 55 5555 5 5 5 5 5 5 66 6666 6 6 6 6 6 6 77 7777 7 7 7 7 7 7 88 8888 8 8 8 8 8 8 99 9999 9 9 9 9 9 9 0005 0 0 0 0 Qa aaaa a a a a The right side of the LED display will be blank after the ML Trim has completed the display variations The ML Trim automatically exits the test Press CODE SELECT only if you want to exit diagnostics Keypad Test 3 To Test the Keypad Press the UP or DOWN scroll keys until the diagnostic indicator and the number 3 are visible on the left side of the LED display Press Enter to start the test The ML Trim displays the number 15 for the Enter key Press each of the keypad keys and verify against the following list Press Display 0 1 1 2 2 3 3 4 4 5 5 6 6 F 7 8 8 9 9 CODE SELECT 10 SETPOINT 11 TACH 12 A 13 v 14 ENTER 15 CLEAR No display If Clear is functioning pressing Clear will take you out of the Keypad test If Clear is not functioning it will not take you out of the test and the number of the prior key will remain on the LED display Press Clear to exit the test Press CODE SELECT only if you want to exit diagnostics Input Test 4 To Test t
9. Humidity 0 95 RH non condensing Environment Pollution degree 2 macro environment Altitude To 3300 feet 1000 meters NOTE Allow adequate spacing between the ML Trim and other equipment to provide for proper heat convection Placing the ML Trim too close to adjacent equipment could cause the interior ambient temperature to exceed 55 degrees C Spacing requirements depend on air flow and enclosure construction 2 The dimensions for the door panel cutout are 3 65 03 x 3 65 03 see Figure 2 1 Allow two inches of clearance on all sides of the cutout for mounting clamp attachments wire routing and heat convection Insert the ML Trim through the door panel cutout until the gasket and bezel are flush with the door panel see Figure 2 1 Slide the mounting clamps into the slots that are located on the top and bottom of the ML Trim Tighten the mounting screws until the ML Trim is mounted securely in the NEMA Electrical Enclosure Do not overtighten e49U95 ui4 1IN z z 61 00c JOPOW WH I A OVA 062 esf LE6L OOCE Jepou WHI 7 TIN OVA SLL SN x A ddng Ni e en RUE 10 na m N3 Aud S gt 40 1n9N x od A x meres 55 wuiodies ZH 09 08 sesny 193MO O Y OO 104 1S9N N cc L0 HASEN O ab Oz Lu H3MOd OV a 4015 4 OTTO dOLS 4 o
10. 15 10s is 1000s 1005 10s 1s FORM ee E o RUN The following is a description of the Control Command Send Host Transmission Character 1 STX This is the first character in the character string None of the other characters will be recognized without this character prefix Always use the ASCII STX character it enables the ML Trims receive buffer Characters 2 3 Device These characters are the access address of the ML Trim This number identifies individual ML Trims on a mutltidrop system The ML Trim will accept data only if this number matches the ML Trim s address CP 70 with the exception of a 00 address The 00 address is universally accepted by all ML Trims that are on the RS485 Serial Communications Interface Character 4 Message Type This character should always be 1 Characters 5 6 Parameter Number These characters should always be 0 Characters 7 through 8 DATA These characters should always be 0 Characters 9 10 DATA 01 F Stop 02 R Stop 03 Run 04 Enable Master Mode 05 Enable Follower Mode 06 Not in Use 07 Not in Use 08 Not in Use 09 Not in Use 10 Enable Setpoint 1 3 11 Enable Setpoint 2 4 12 Not in Use 13 Not in Use 14 Not in Use 15 Not in Use Character 11 Data Format This character should always be 0 Character 12 ETX Always use the ASCII ETX character to terminate the charact
11. 5 dois y O O EH 4015 9 6 ES Bor oH 452 Es E O_O LN o ro 5 iia L 70 gt DIS DIS uny SEF J ET 3350 uq 10suas WOO noo Zn 6xz Aouenbal4 DIS yaad S 5 2 par ___ of ava S 2 10suag woo woo LEA gt E DIS LL pon 54 ENS 0253 WOO peo 5 E 5 E Qu aL as f lt 11195 9859 A ddns mos ast DAAS WIRING This section contains the input output and serial communications wiring information for the ML Trim Please read this section prior to wiring the ML Trim to ensure that you make the appropriate wiring decisions NOTE The installation of this motor control must conform to area and local electrical codes See The National Electrical Code NEC Article 430 published by the National Fire Protection Association or The Canadian Electrical Code CEC Use local codes as applicable Use a minimum wire gauge of 18 AWG Use shielded cable to minimize equipment malfunctions from electrical noise Keep the AC power wiring J3 physically separated from all other wiring on the ML Trim Failure to do so could result in additional electrical noise and cause the ML Trim to malfunction A hand operated supply disconnect device must be installed in the final applica
12. ML Trim The Clear 7 procedure restores the factory default settings and automatically performs the Power Up diagnostic routines Reenter your Code Parameters values Insert Tool Here U4 LN Insert Tool Here Beveled Corner LIEFERT TER Figure 4 5 PROM Location 18 NOTES Glossary GLOSSARY Acceleration Deceleration Acceleration Time CP 16 and Deceleration Time CP 17 control the rate of speed change in response to setpoint changes These parameters apply to both the Master and Follower modes of operation Acceleration Time See Appendix C CP 16 Alarms See Appendix C CP 10 12 13 14 or 15 Calibration Calibration matches the analog output of the ML Trim with the analog input of the motor drive Closed loop A system that is controlled by manipulating the output based on error setpoint feedback Closed Loop Compensation A mathematical term for a control algorithm that resolves PID Software the control error feedback setpoint to zero Output Kp X Error K Error dt dError dt PID represents Proportional Integral Derivative Code Select Key Press this key prior to entering a Parameter Code either a Control Parameter or a Monitor Parameter Control Command Send The Control Command Send allows the host computer to control the operating functions of the ML Trim that are associated with the Logic inputs Run Stop Setpoint Sel
13. Max RPM Feedback CP 34 to scale for the Master mode of operation Refer to Operation Contro Parameters Master Mode page 3 9 Check the speed RPMs by pressing the Tach key If the lowest setting on the ML Trim s Maximum Speed Potentiometer still exceeds the maximum speed at which you want the system to operate then adjust the Maximum Speed Span Potentiometer on the motor drive until the desired speed is reached Put the Direct Setpoint back to 096 by entering the following on the keypad Press Code Select Enter 6 Direct Setpoint Press Enter Enter 0 Press Enter Disable the ML Trim s Direct mode by entering the following on the keypad Press Code Select Enter 61 Direct Enable Press Enter Enter 0 Press Enter 10 Put the ML Trim in R Stop by opening the R Stop input J5 pins 9 11 Refer to Installation Setup Wiring Inputs R Stop page 2 10 Operation Keypad Operation Keypad Lockout Control Parameters CP Direct Mode Master Mode Follower Mode Inverse Master Mode Inverse Follower Mode Acceleration Deceleration Tuning Alarms Jog Logic Control Logic Inputs Logic Outputs Monitor Parameters MP Input Monitoring Output Monitoring Performance Monitoring Status Monitoring Serial Communications Using Serial Communications Communications Software Design KEYPAD OPERATION The front panel of the ML Trim is an easy to use keypad that gives you direct acc
14. Stop has the second highest operating state priority RAM Test Tests Random Access Memory This test can be run as part of the diagnostic tests It is also one of the two power up diagnostic routines that the ML Trim automatically performs during every Power Up RPM Feedback The speed of the feedback sensor in revolutions per minute RPM Lead The speed of the lead sensor in revolutions per minute Run One of four operating states Run ramps to the scaled setpoint speed using the acceleration and deceleration rate values in Acceleration Time CP 16 and Deceleration Time CP 17 Run can be activated when the ML Trim is in R Stop or F Stop however Run cannot be activated when the ML Trim is in Jog Run has the third highest operating state priority Scaling Scaling Control Parameters supply the ML Trim with the information that it needs to calculate the ratio of RPM s to Engineering Units and run at the entered setpoint Glossary 9 Scroll Up Down Keys Serial Communications Status Monitoring Glossary 10 These keys change the active setpoint value even if the active setpoint is not displayed in the LED display Each time you press the Scroll Up key the active setpoint will increase by one increment Each time you press the Scroll Down key the active setpoint value will decrease by one increment Press and hold the key to automatically scroll through the increments or decrements The ML Trim can interface with a host
15. Warranty SERVICE POLICY Contrex Inc recognizes that with each sale of its product there are certain product obligations This document defines the limits of such obligations and provides guidelines for the performance of related services Applicability This Service Policy shall apply to all product sales of Contrex Inc However it may be modified by mutual consent Thus whenever an accepted proposal contains wording inconsistent with this policy the proposal will prevail with respect to specific sale or series of sales involved Applicability of this policy is also somewhat limited in cases where products are sold to an OEM for resale to user See paragraph below entitled OEM Service Service Personnel Contrex Inc has a staff whose primary responsibility is service both factory service and field on site service Personnel of this department are usually available for service on a 24 hour notice To facilitate quicker handling of service requests either written or by phone such requests should be directed to the Contrex Inc Technical Services Department Service Charges Contrex Inc reserves the right to charge for all services performed at the customers request with the exception of factory service performed under warranty All on site service is charged at flat rate per diem rates plus expenses Any Contrex Inc product developing defects as defined in the warranty during its effective period will be re
16. drive If the motor drive has a potentiometer speed control remove the potentiometer connections and wire the Speed Command Output to the potentiometer wiper input The ML Trim s isolated common should always be connected to the drive common Drive Enable J5 pin 16 SIGNAL INPUT Speed Command Out DRIVE COMMON Isolated Common MOTOR DRIVE Do not connect the Drive Isolated Common to other Logic Commons Figure 2 14 Speed Command Out The Drive Enable output is activated driven low when the ML Trim is signaling a nonzero speed command to the motor drive as defined by Drive Enable Logic CP 74 The Drive Enable output is driven high relay deactivated after Power Up and during R Stop and F Stop See Figure 2 15 Refer to Operations Logic Control Logic Output page 3 37 for details NOTE This is an open collector relay driver For specification details see References Appendix A ML Trim Specifications page A 1 Use an external DC power supply to power the relays Free wheeling diodes are incorporated internally in the ML Trim and do not need to be added externally 14 Alarm J5 pin 17 By entering alarm Control Parameters you can establish circumstances under which the ML Trim will alert you to potential operating problems The alarm can be wired to activate a warning light a warning sound or to shut down the system under specified conditions Alarm Format CP 10 determines which alarm conditions
17. follow Parameter Send Use the Parameter Send to change any of the ML Trim s Control Parameters Table 3 29 Parameter Send Host Transmission DEV DEV 2 MSG PAR 4 PAR DATA DATA DATA DATA DATA DESC STX 10s 15 10s 15 1000s 1005 10s 1s FORM asen jem os 09 s os os os os 09 os os The following is a description of the Parameter Send Host Transmission Characters Character 1 STX This is the first character in the character string None of the other characters will be recognized without this character prefix Always use the ASCII STX character it enables the ML Trim s receive buffer Characters 2 3 Device These characters are the access address of the ML Trim This number identifies individual ML Trims on a multidrop system The ML Trim will accept data only if this number matches the ML Trim s address CP 70 with the exception of a 00 address The 00 address is universally accepted by all of the ML Trims that are on the RS485 Serial Communications Interface Character 4 Message Type This character should always be 3 54 Character 5 6 Parameter Number These characters identify the Control Parameter that you want to change i e 16 CP 16 Characters 7 through 10 DATA These characters transmit the new value for a Control Parameter that you want to change The Data must be within the range specified in Appendix D Charac
18. for instructions on the Clear 7 procedure If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Record your numeric Keypad Lockout password here Please read the CAUTION statement on Page 3 5 CONTROL PARAMETERS Parameters are divided into two classifications Control Parameters CP and Monitor Parameters MP The numbered code that represents the Parameter is the Parameter Code The operational data is the Parameter s value Control Parameter 05 50 Parameters Monitor Parameter 40 200 arbitrary Parameter Code Parameter Value This section is about Control Parameters Monitor Parameters are explained in Operation Monitor Parameters page 3 39 The ML Trim comes factory pre loaded with a complete set of default Control Parameters values The majority of these default settings are suitable for most applications and do not require modification Control Parameters allow you to enter data that is unique to your system e g encoder resolution Lead to Follower ratios and modify the ML Trim for your specific needs e g maximum RPMS setpoints acceleration deceleration ramp rates by entering a parameter value The ML Trim is designed to execute either the Direct mode of operation the Master stand alone mode of operation or the Follower mode of operation The values that you enter in the relevant Control Parameters as well as the manner in which you wire a
19. host computer the Error Code will display them Use Table 3 35 page 3 66 to convert the ASCII code to binary The binary code can be decoded as follows Bit 7 Always 0 Bit 6 Always 1 Bit 5 1 Data was out of minimum maximum range Bit 4 1 Checksum or Decimal Point Error Invalid Parameter Code Bit 3 1 Receive buffer filled before ETX received or Message Format Error Bit 2 1 Invalid Parameter Data Bit 1 1 Parity Error Bit 0 1 Always 0 Note The ML Trim will only accept data if there are no errors The ASCII error code O Binary code 1000000 indicates that the Host Transmission contains no errors Characters 5 6 Parameter Number The Control Parameter code is sent back to the host computer from the ML Trim Characters 7 through 10 DATA The Control Parameter data is sent back to the host computer from the ML Trim Character 11 Data Format The Data Format character is sent back to the host computer from the ML Trim Character 12 ETX The return message is always terminated with the ASCII ETX character 57 Control Command Send The Control Command Send allows the host computer to control the operating functions of the ML Trim that are associated with the digital inputs Run Stop Setpoint Select and Master Follower Table 3 31 Control Command Send Host Transmission a DEV DEV MSG PAR 4 PAR DATA DATA DATA DATA DATA DESC STX 10s
20. ratio of Max RPM Feedback CP 34 to Max RPM Lead CP 33 or the ratio of Follower to Lead Engineering Units at maximum desired RPM When this number is also entered as a setpoint CP 03 or CP 04 the Follower will operate at maximum desired RPM when the Lead is at maximum desired RPM The factory default Control Parameters for Scaling are found on Table 3 8 To modify these default parameters refer to Table 3 9 If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Table 3 8 Default Follower Scaling Control Parameters CP Parameter Name Parameter Value CP 33 Max RPM Lead 2000 CP 34 Max RPM Feedback 2000 CP 21 Follower Engineering Units Table 3 9 Entering Follower Scaling Control Parameters Parameter Name Parameter Value CP 33 Max RPM Lead Enter the maximum operating RPM of the Lead motor measured at the Lead sensor shaft pulses per revolution CP 34 Max RPM Feedback Enter the maximum desired RPM of the Follower motor measured at the Follower feedback sensor shaft CP 33 PPR Lead Enter the number of gear teeth or encoder lines on the Lead sensor 31 PPR Feedback Enter the number of gear teeth or encoder lines on the Follower feedback sensor CP 21 Follower Engineering Units Enter the Engineering Units value if the Lead CP 33 is operating at maximum RPM and the Follower CP 34 is operating at maximum RPM With your scaling established y
21. require greater accuracy it may be necessary to adjust the value of Integral CP 66 to reduce any remaining speed error In systems with low inertia the speed error will be reduced more quickly if you enter low values in Integral CP 66 An entry that is too low however can create instability or overshoot the setpoint before reaching the correct value Generally use larger entries for Integral CP 66 on systems with a large inertia While switching between the high and low setpoints decrease the Integral s default value of 2000 until the speed error is reduced within an acceptable time frame To verify the stability of the speed changes you can access Tach through either the tach key or the Tach MP 40 CP 67 DERIVATIVE In systems with a very large inertia use Derivative CP 67 to reduce the overshoot from the integral term Decrease the value of Derivative CP 67 until the overshoot is acceptable The system may operate erratically or become unstable if the value of Derivative CP 67 is too small CP 70 DEVICE ADDRESS Device Address CP 70 is the physical address of the ML Trim which can be set from 1 to 32 Each individual ML Trim on a multidrop RS485 communications link needs a unique Device Address The address 00 will be globally accepted by all of the ML Trims on a communications link however they will not send a response message back to the host computer when this global address is used CP 71 BAUD RATE T
22. revision number of the ML Trim software PROM MP 00 SOFTWARE PART NUMBER Software Part Number MP 00 displays last four digits of the software part number for the ML Trim The first four digits of the part number are assumed to be 1000 APPENDIX D CONTROL PARAMETER REFERENCE USER DESCRIPTION MAX DEFAULT aizel DE UNITS Master Setpoint 1 Master Setpoint 2 Follower Setpoint 1 Follower Setpoint 2 Jog Setpoint Direct Setpoint Alarm Format Low Alarm High Alarm Ramped Error Alarm Scaled Error Alarm Acceleration Time Deceleration Time Master Eng Units Follower Eng Units PPR Lead PPR Feedback Max RPM Lead Max RPM Feedback Direct Enable Inverse Scaling Display Mode Follower Gain Integral Derivative Device Address Baud Rate Character Format Control Mask Drive Enable Logic Keypad Lockout oo o0 0 ll NOTES APPENDIX E MONITOR PARAMETER REFERENCE DESCRIPTION Tach Lead Frequency HZ Feedback Frequency HZ Deviation Error HZ Scaled Reference HZ Ramped Reference HZ Speed Command Output Trim Output DAC BITS Active Scaling Mode CODED Keypad Error CODED Alarm Status CODED Control State CODED Logic Inputs Group A CODED Logic Inputs Group B CODED Logic Outputs CODED EEPROM Status CODED Serial Comm Error CODED Frequency Overflow Counter COUNTS Software Code Revision Software Part Number NOTES APPENDIX F ML TRIM FAX COVER SHEET Date Att
23. shaft is equipped with a 60 tooth Ring kit Follower Setpoint 1 will be set so that when the Lead pump delivers 20 gallons minute of ingredient A the Follower will deliver 10 gallons minute of ingredient B Setpoint 2 will be set so when the Lead pump delivers 10 gallons minute of ingredient A the Follower pump will delivers 7 gallons minute of ingredient B Table 3 12 shows the Control Parameters that would be entered in the ML Trim for Example B To find the ratio for the Follower Engineering Units CP 21 for Example B Follower E U at Max Follower RPM 10 Follower E U CP 21 X 100 50 Lead E U at Max Lead RPM 20 10 gal min The Follower Engineering Units when the Follower is operating at maximum RPM Divided by 20 gal min The Lead Engineering Units when the Lead is operating at maximum RPM Multiplied by 100 equals 50 Follower Engineering Units CP 21 as a percent of Follower to Lead 20 To find Follower Setpoint 1 CP 03 for Example B Follower E U desired Setpoint 1 x 100 Lead E U operation 10 gal min The Follower Engineering Units gallons minute of ingredient B at which you want the Follower to operate do not confuse this with the full capacity that the Follower is capable of pumping Divided by 20 gal min The Lead Engineering Units gallons minute of ingredient A that the Lead is operating at do not confuse this with the full capacity that the Lead is capable of operating
24. 1 Table 3 35 ASCII to Binary ASCII Binary ASCII Binary ASCII Binary ASCII Binary Bit7 Bit 1 Bit7 Bit 1 Bit7 Bit 1 0100000 0100001 0100010 0100011 0100100 0100101 0100110 0100111 0101000 0101001 0101010 0101011 0101100 0101101 0101110 0101111 0110000 0110001 0110010 0110011 0110100 0110101 0110110 0110111 0111000 0111001 0111010 0111011 0111100 0111101 0111110 0111111 N XxE E c omJouozzm xc rgommoou G 1000000 1000001 1000010 1000011 1000100 1000101 1000110 1000111 1001000 1001001 1001010 1001011 1001100 1001101 1001110 1001111 1010000 1010001 1010010 1010011 1010100 1010101 1010110 1010111 1011000 1011001 1011010 1011011 1011100 1011101 1011110 1011111 lt lt lt gt lt gt 0 m r 1100000 1100001 1100010 1100011 1100100 1100101 1100110 1100111 1101000 1101001 1101010 1101011 1101100 1101101 1101110 1101111 1110000 1110001 1110010 1110011 1110100 1110101 1110110 1110111 1111000 1111001 1111010 1111011 1111100 1111101 1111110 1111111 RES uodas 04 PASEN 015 5 JOWUOW Aleu g 9 esn ul JON esn ul 10N MO MO elqeuz esp ul JON esf ul 10N 7102 qulodjes JOISEN siaquiny
25. 3 1 0 Power Isolated damage the equipment Do not exceed 5VDC on the I O Power Input Use the Auxiliary Power Output J4 pins 1 2 to supply power to non isolated operations The ML Trim is shipped from the factory with the wiring defaulted to the non isolated operation Figure 2 4 Power Non Isolated AC Power J3 pins 1 2 3 The ML Trim model 3200 1931 operates on 115 VAC 15 0 1 Amp 50 60 Hz The ML Trim model L1 13200 1932 operates 230 VAC 15 0 1 Amp 50 60 Hz Neutral or L2 GND PE Fuse L1 for 115VAC applica tions Fuse L1 and L2 for 230VAC applications Use 1 Amp 250V normal blow fuses Figure 2 5 Input Power Lead Frequency J5 pins 3 5 The Lead Frequency is a pulse train input that the ML Trim uses to determine the speed of the lead motor For signal level specifications Signal refer to References Appendix A ML Trim Specifications page A 1 Common Figure 2 6 Lead Frequency Feedback Frequency J5 pins 4 5 The Feedback Frequency is a pulse train input that the ML Trim uses to determine the speed of the follower motor For signal level specifications Common refer to References Appendix A u ML Trim Specifications page A 1 Signal Figure 2 7 Feedback Frequency DANGER If the Feedback Frequency is lost the ML Trim will command a 100 Speed Out and the motor will run at 100 capacity This can cause severe injury death or equipment d
26. 3 66 Binary to Monitor Parameters 3 67 Introduction Introducing the ML Trim Examples of ML Trim Applications INTRODUCING THE ML TRIM The ML Trim is a highly accurate digital motor controller It has advanced embedded software that is capable of solving a great variety of speed control tasks It operates as either a stand alone control of a single motor Master mode or as a part of a complex multi drive system Follower mode The ML Trim is ideal for motor control applications where your present open loop or rudimentary closed loop operations are inaccurate or where there is inadequate load regulation The ML Trim adds accurate digital control to virtually any AC DC Servo Flux Vector or Clutch drives The ML Trim is also at the forefront in digitally accurate Follower applications See Figure 1 1 and Figure 1 2 for examples of Master and Follower applications The ML Trim is unique among its competition because the ML Trim has preprogramed software that integrates with your system with little effort from you The ML Trim will also allow you to enter data that is unique to your system s specific needs e g maximum RPMs setpoints acceleration deceleration ramp rates Using Control Parameters CPs this data is entered through either the ML Trim s integrated keypad or though a host computer via the RS485 Serial Communications port In addition to the Control Parameters that allow
27. 49 Glossary 10 ASCII Messages page 3 52 Binary Messages page 3 52 Connections page 2 16 Control Command Send page 3 58 Data Inquiry page 3 62 Error page 3 51 C 10 E 1 Multidrop Installation page 2 15 Parameter Send page 3 53 Service Policy page Warranty 3 Setpoint Select Input J5 pins 13 14 page 2 12 Setup Calibration page 2 17 Mounting the ML Trim page 2 3 Wiring page 2 5 Software Code Revision page C 14 E 1 Design Communications page 3 52 Part Number page C 14 E 1 Specifications ML Trim page A 1 Speed Command Out page 3 42 C 6 E 1 Output J2 pins 1 2 page 2 13 Status Monitoring page 3 45 Glossary 10 Support Technical See Technical Support T Tach page 3 43 C 4 E 1 Technical Support page ii 4 3 4 11 Index 10 Test Random Access Memory page 4 4 The Keypad page 4 6 The LED Display Panel Segments page 4 5 The Logic Inputs page 4 7 The Logic Outputs page 4 8 The Speed Command Output page 4 9 Trim Output page 3 44 C 6 E 1 Troubleshooting page 4 11 Motor Does Not Run page 4 13 Motor Does Not Stop Flowchart page 4 12 Motor Runs at Wrong Speed page 4 14 Motor Runs Unstable page 4 15 Tuning page 3 27 Glossary 9 U ULOC page 3 5 W Warranty page Warranty 4 Wiring Connections Relay Start Stop page G 2 Connections without Relays page G 1 Examples page G 1 General Diagram page 2 4 Inputs page 2 7 Outputs page 2 13 Start Stop for Non Regen with
28. 54 LOGIC INPUTS GROUPA The Logic Inputs A displays the status of the Run Jog R Stop and F Stop digital inputs The number 1 indicates an open or logic high level The number 0 indicates a closed or logic low level shorted to common In the example below Jog is the open or logic high level Code Run J5 Pin 6 Jog J5 Pin 7 R Stop J5 Pin 9 F Stop J5 Pin 10 MP 55 LOGIC INPUTS GROUP B The Logic Inputs B displays the status of the Master Follower and Setpoint Select digital inputs The number 1 indicates an open or logic high level The number 0 indicates a closed or logic low level shorted to common In the example below Setpoint Select is the open or logic high level Code Master or Follower J5 Pin 12 Setpoint Select J5 Pin 13 Not Used Not Used 42 Output Monitoring These MPs monitor the ML Trim s outputs MP 47 SPEED COMMAND OUT The Speed Command Out MP 47 displays the level of calibrated full scale analog output to the motor drive J2 pin 1 The Speed Command Out MP 47 is displayed as a percentage 100 represents 100 of the calibrated full scale analog output MP 56 LOGIC OUTPUTS The Logic Outputs MP 56 displays the status of the Drive Enable and the Alarm digital outputs The number 1 indicates an inactive or de energized logic high level The number 0 indicates an active or energized logic low level In the example below Alarm is
29. 8 displays the present status of the keypad lockout When the keypad is locked then LOC is displayed Code E When the Keypad is unlocked then ULOC is displayed Code PS To lock out the keypad enter a numerical password between 1 and 9999 in Keypad Lockout CP 98 then press the enter key This numerical password will flash briefly on the screen then the screen will display LOC To unlock the keypad enter the same numerical password in Keypad Lockout CP 98 The number will flash briefly on the screen and then the screen will display ULOC Control Parameters and Monitor Parameters may be monitored during lockout however Control Parameters can not be changed during lockout The Clear 7 procedure will default Keypad Lockout CP 98 to ULOC unlocked CAUTION Make certain that you record your password in the space provided on page 3 6 as your password becomes transparent once you have entered it If you forget your password you can use the Clear 7 procedure to revert back to the default ULOC unlocked Please note however that the Clear 7 procedure will revert all of the Control Parameters back to their original default values and you will lose any changes that you have made to the Control Parameters Therefore make certain that you have recorded all Control Parameter changes in the space provided in Appendix D before you use the Clear 7 procedure Refer to Troubleshooting Troubleshooting page 4 11
30. Active Scaling Mode page 3 45 C 6 E 1 Alarm Format page 3 29 C 2 D 1 Output J5 pin 17 page 2 14 Status page 3 46 C 7 E 1 Alarms grouped page 3 29 Appendix A page A 1 Appendix B page B 1 Appendix C page C 1 Appendix D page D 1 Appendix E page E 1 Appendix F page F 1 Appendix G page G 1 Appendix H page H 1 ASCII Serial Communications Messages page 3 52 B Baud Rate page 3 50 C 12 D 1 Binary Serial Communications Messages page 3 52 C Calibration page 2 17 Definition page Glossary 3 ML Trim page 2 19 Character Format page 3 51 C 12 D 1 Clear 4 page 4 3 Clear 7 page 4 11 Closed Loop page 1 3 Glossary 3 Closed Loop Compensation page Glossary 3 Connections Serial Communications page 2 16 Control Command Send page Glossary 3 Serial Communications page 3 58 Control Mask page 3 51 C 13 D 1 Control Parameter Reference List page D 1 Index 3 Control Parameters page 3 7 Glossary 3 CP 01 page 3 9 3 10 3 11 3 23 C 1 D 1 CP 02 page 3 9 3 10 3 11 3 23 C 1 D 1 CP 03 page 3 13 3 15 3 21 3 25 C 1 D 1 CP 04 page 3 13 3 15 3 21 3 25 C 1 D 1 CP 05 page 3 31 C 1 D 1 CP 06 page 3 8 C 2 D 1 CP 10 page 3 29 C 2 D 1 CP 12 page 3 29 C 2 D 1 CP 13 page 3 29 C 2 D 1 CP 14 page 3 29 C 2 D 1 CP 15 page 3 29 C 3 D 1 CP 16 page 3 26 C 3 D 1 CP 17 page 3 26 C 3 D 1 CP 20 page 3 9 C 3 D 1 CP 21 page 3 13 C 3 D 1 CP 30 page 3 13 C 3 D 1 CP 31
31. Armature page G 4 Start Stop for Regen with Armature page G 3 Two Channel Start Stop Lead or Follower page G 5 Index 11 NOTES Index 12
32. Control Parameter entry has been rejected Keypad Error MP 51 will ascertain the reason that it was rejected The digit that displays a number 1 is the error In the example below Above Maximum Allowed Value is the error Code Invalid Code Parameter Above Maximum Allowed Value Below Minimum Allowed Value Entry Timeout MP 52 ALARM STATUS Alarm Status MP 52 displays a number 1 to indicate the active alarm In the example below High Speed Alarm is the active alarm Code Low Speed Alarm High Speed Alarm Ramped Error Scaled Error MP 53 CONTROL STATE Control State MP 53 displays a number 1 to indicate the active control state of the ML Trim In the example below Run is the active control state Code MP 54 LOGIC INPUTS GROUP A The Logic Inputs Group A MP 54 displays the status of the Run Jog R Stop and F Stop logic inputs The number 1 indicates an open or logic high level The number 0 indicates a closed or logic low level shorted to common In the example below is the open or logic high level Code Run J5 Pin 6 Jog J5 Pin 7 R Stop J5 Pin 9 F Stop J5 Pin 10 MP 55 LOGIC INPUTS GROUP B The Logic Inputs Group B MP 55 displays the status of the Master Follower and Setpoint Select logic inputs The number 1 indicates an open or logic high level The number 0 indicates a closed or logic low level shorted to c
33. Corrected Decrease Max Speed Increase Max Speed Figure 4 3 Motor Runs at Wrong Speed Flowchart Motor Runs Unstable Change CP 61 to 1 and Run in Direct Mode Motor Still Unstable Change CP 61 to 0 and run in Master Mode Check Drive Calibration Repeat Tuning Procedure Problem Corrected Consult Tech Support 1 800 342 4411 Figure 4 4 Motor Runs Unstable Flowchart PROM CHIP REPLACEMENT The PROM Programmable Read Only Memory chip is the software for the ML Trim See Figure 4 5 for the PROM s location on the CPU Board To replace the PROM chip Make a record of your current Control Parameter values the replacement chip contains default values that will replace your current values when you perform the Clear 7 step Turn off the power to the ML Trim Remove the back panel Pull out the CPU board Ground yourself Static electricity can damage the PROM Locate the PROM chip and carefully pry the PROM from the socket Alternate between the two corners as noted in figure 4 5 Carefully install the replacement PROM in the socket by lining up the beveled corner of the PROM chip with the beveled corner of the socket Apply even pressure until the PROM is seated NOTE Incorrect placement can damage the PROM Replace the CPU board Replace the back panel Press the Clear key and 7 key then continue to press the keys while you apply power to the
34. Feedback Press Enter Enter the Pulses Per Revolution PPR of the feedback sensor Press Enter The Tach for the Direct mode is now scaled Set the ML Trim s Maximum Speed Potentiometer located on the rear as far counter clockwise as it will turn This is the minimum speed setting Enable the ML Trim s Direct mode by entering the following on the keypad Press Code Select Enter 61 Direct Enable Press Enter Enter 1 Press Enter Put the ML Trim into Run by deactivating shorting the R Stop input J5 pins 9 11 and the F Stop input J5 pins 10 11 and then activating shorting the Run input J5 pins 6 8 Although the motor is now in it will have zero speed until you adjust the Direct Setpoint in the next step Gradually set the ML Trim s Direct Setpoint to 90 by entering the following on the keypad Press Code Select Enter 6 Direct Setpoint Press Enter Enter 10 Press Enter Enter 20 Press Enter 8 9 Continue to gradually increase these increments by ten until you reach 90 Since there are no acceleration deceleration ramps in Direct mode a sudden increase to 90 could cause damage in some systems Turn the ML Trim s Maximum Speed Potentiometer clockwise until the drive motor s RPMs are at the maximum operating speed at which you want the system to operate The maximum operating speed is the same speed that you will enter in
35. ML Trim User Manual 0001 0127 Revision C Technical Assistance If you have comments or questions concerning the operation of the ML Trim please call us A member of our Technical Support Staff will be happy to assist you Ask for Technical Support 763 424 7800 or 1 800 342 4411 Contrex 8900 Zachary Lane North Maple Grove Minnesota 55369 Copyright 1998 Contrex MN DANGER Improper installation can 1 cause severe injury death or damage to your system Integrate this motion control unit into your system with caution Operate this motion control unit only under the conditions prescribed in this manual Any other use shall be deemed inappropriate Comply with the National Electrical Code and all applicable local and national codes iv Table of Contents Introduction 1 1 Introducing the 1 3 Examples of ML Trim 1 4 Installation Setup cese 2 1 MOUNINO reu tee D e ide EI eet Md 2 3 WIEIDQ s iiio do e o a E OE REESE inus 2 5 eS 2 7 OUIpUIS oie ee he Dea as tst Mt eL 2 13 Serial Communications eese 7 2 15 2 17 Motor Drive Set 0 00 4 000000 0 2 18 ML Trim Calibrations 2 19 er 3 1 AER
36. NTER The Frequency Over Flow Counter MP 59 is a counter that increments each time the frequency input to the ML Trim causes an overflow To reset the counter to 0 press the Clear key 48 NOTES SERIAL COMMUNICATIONS The ML Trim can interface with a host computer through a RS485 Serial Communications Interface This interface allows the host computer to perform remote Control Parameter entry status or performance monitoring and remote control of the ML Trim Refer to Using Serial Communications page 3 50 in this section If you are using the M Host software your communications network is user ready and does not require any software programming M Host software is available through your distributor If you are designing your own software refer to Communications Software Design page 3 52 in this section Once the software is installed you are ready to establish a link through the Serial Communications Interface 50 Using Serial Communications This section describes how to use the Serial Communications Before you can apply this section The ML Trim must be interfaced with a host computer through a RS485 Serial Communications Interface The host computer must have the M Host software or its equivalent installed The ML Trim comes factory pre loaded with default Control Parameters for Serial Communications Setup These Control Parameters physically set up the ML Trim to accommodate the RS485 Serial Communicat
37. P 31 is the number of gear teeth or number of encoder lines on the Follower feedback sensor per revolution pulses per revolution CP 33 MAX RPM LEAD Measured at the Lead sensor shaft Max RPM Lead CP 33 is the maximum RPMs at which the Lead will operate your system This number is not to be confused with the full capacity at which the Lead is capable of running A system is not generally run at full capacity CP 34 MAX RPM FEEDBACK Measured at the sensor shaft Max RPM Feedback CP 34 is the maximum RPMs at which you want your system to operate and is not to be confused with the full capacity at which your system is capable of running A system is not generally run at full capacity This number is identical to the maximum operating speed that you set in step 7 of the calibration procedure page 2 20 MP 40 TACH In the Master mode Tach MP 40 will display the feedback in Master Engineering Units CP 20 In the Follower mode Tach MP 40 will display either the E U s Time or the feedback to Lead ratio in Follower Engineering Units CP 21 depending on the value in Display Mode Follower CP 64 In Jog or the Direct mode Tach MP 40 will display the feedback in RPMs The feedback is read by the ML Trim every ten milliseconds The readings are summed then averaged for one second before the Tach is displayed MP 41 LEAD FREQUENCY The Lead Frequency MP 41 displays the frequency of the Lead Frequency Input J5 pin 3 in units of
38. Power Non lsolated 2 7 AG POWO antics ec AR eO 2 8 Lead Frequency 2 8 Feedback Frequency 2 9 re Na 2 9 SOG os ots tees d Boks coy ed lates 2 10 R SIOD uni m nnl 2 10 joo ED 2 11 Master or 2 11 Setpoint 44400000 0 2 12 Speed Command 2 13 Drive Enable and Alarms Outputs 2 14 ML Trim Multidrop Installation eeeseeee 2 15 ML Trim Serial Communications Connections 2 16 ML Trim Front Panel essen 3 4 ML Trim Internal Structure 3 43 Motor Does Not Stop Flowchart 4 12 Motor Does Not Run Flowchart 4 13 Motor Runs at Wrong Speed Flowchart 4 14 Motor Runs Unstable Flowchart 4 15 PROM Localia ad 4 17 ML Trim Wiring Connections without Relays G 1 Relay Start Stop Wiring Connections G 2 Start Stop for Regen with Armature Contactor G 3 Start Stop for Non Regen with Armature Contactor G 4 Two Channel Start Stop Lead Follower Logic G 5
39. RIAL COMMUNICATIONS ERROR Serial Communications Error identifies errors in the last transmitted message that was sent to the ML Trim by the host computer The mode that displays a number 1 indicates the error In the example below Invalid Parameter Code is the error Code Structure Error Parity Framing No ETX No STX Invalid Parameter Code Invalid Parameter Data or Out of Data Min Max Range Control Mask Error Communications Software Design The ML Trim Serial Communications Interface uses a polling technique to establish a link with the host computer With the exception of Keypad Lockout CP 98 all of the Control Parameters and Monitor Parameters that are accessible through the ML Trim s front panel keypad are also accessible through the Serial Communications Interface The host computer sends a twelve character record to the ML Trim to establish the link and the ML Trim responds with either a conformation or an error message Once the ML Trim responds the host computer can send additional transmissions All of the ML Trim s messages use the USA Standard Code for Information Interchange ASCII The host computer sends three types of messages Parameter Send To change CPs Control Command Send To control operating states Data Inquiry To monitor CPs and MPs These three message types their character level descriptions in binary and ASCII as well as the ML Trim s response record are outlined in the sections that
40. alarm can be wired to activate a warning light a warning sound or to shut down the system under specified conditions Alarm Format CP 10 determines which alarm conditions will activate the Alarm output using the values that are entered in Low Alarm CP 12 High Alarm CP 13 Ramped Error Alarm CP 14 and Scaled Error Alarm CP 15 0 No Alarm 8 Scaled Error 1 Low Alarm 9 LowAlarm or Scaled Error 2 High Alarm 10 High Alarm or Scaled Error 3 Low Alarm or High Alarm 11 Low Alarm or High Alarm or Scaled Error 4 Ramped Error 12 Ramped Error or Scaled Error 5 Low Alarm or Ramped Error 13 Low Alarm or Ramped Error or Scaled Error 6 High Alarm or Ramped Error 14 High Alarm Ramped Error or Scaled Error 7 Low Alarm or High Alarm 15 Low Alarm or High Alarm or Ramped Error or or Ramped Error Scaled Error CP 12 LOW ALARM Low Alarm CP 12 is the RPMs at or below which you want the Alarm output to activate CP 13 HIGH ALARM High Alarm CP 13 is the RPMs at or above which you want the Alarm output to activate CP 14 RAMPED ERROR ALARM The Ramped Error Alarm CP 14 is the RPM deviation between the ramped reference and the feedback that will activate the Alarm output at or above CP 15 SCALED ERROR ALARM The Scaled Error Alarm CP 15 is the RPM deviation between the scaled reference and the feedback that will activate the Alarm output at or above CP 16 ACCELERATION TIME Acceleration Time
41. amage Run J5 pins 6 8 When the Run input J5 pin 6 is momentarily shorted to common the ML Trim enters Run Asa momentary input Run is internally latched and does not need to be maintained by an operator device NOTE Close the R Stop and F Stop inputs prior to entering Run If you are only using one of the Stop inputs wire short the other Stop input to common or the ML Trim will not enter Figure 2 8 Run Run Jog J5 pins 7 8 Jog is a maintained input When Jog is closed the ML Trim sends a Speed Command Out signal to the drive at the selected jog speed Asa maintained input Jog is only active when the operator device is closed NOTE Close the R Stop and F Stop inputs and open the Run input prior to entering Jog If you are only using one of the Stop inputs wire short the other Stop input to common or the ML Trim will not enter Jog R Stop J5 pins 9 11 R Stop is a momentary input When itis opened the ML Trim ramps to a zero Speed Command Out at the specified deceleration rate As a momentary input R Stop is internally latched and does not need to be maintained by an operator device Figure 2 9 Jog Figure 2 10 R Stop F Stop J5 pins 10 11 F Stop is a momentary input When it is open the ML Trim stops immediately zero RPM and ignores the specified deceleration rate Asa momentary input F Stop is internally latched and does not need to be maintained by an operato
42. ameter Number The Control Parameter code is sent back to the host computer from the ML Trim Characters 7 through 10 DATA The Control Parameter data that was requested is sent back to the host computer from the ML Trim For an interpretation of the MP 50 through MP 56 and CP 73 data refer to Table 3 36 page 3 67 For the ASCII to binary conversion refer to Table 3 35 page 3 66 Character 11 Data Format Character 11 indicates the decimal location and polarity of the data that was transmitted in characters 7 through 10 Use the following codes to indicate decimal location and polarity O O O Format Code Format XXXX 9 XXX X XX XX X XXX X XXX XXXX XXX X XX XX X XXX NOV Codes 0 through 7 are valid for 20 and CP 21 Code 8 is valid for MP 41 MP 43 MP 45 and MP 46 All other Code Parameters have either fixed or derived decimal locations and must use Code 0 For codes 9 and multiply characters 7 through 10 by ten Character 12 ETX The return message is always terminated with the ASCII ETX character 66 0000000 0000001 0000010 000001 1 0000100 0000101 0000110 00001 11 0001000 0001001 0001010 000101 1 0001100 0001101 0001110 0001111 0010000 0010001 0010010 001001 1 0010100 0010101 0010110 0010111 0011000 0011001 0011010 0011011 0011100 0011101 0011110 001111
43. ary 3 ui eene antes an A 1 Appendix A ML Trim A 1 Appendix B Eormulas edet B 1 Appendix C Parameter Summary numeric quick reference C 1 Appendix D Control Parameter Reference D 1 Appendix E Monitor Parameter Reference E 1 Appendix ML Trim Fax Cover Sheet F 1 Appendix Wiring Diagram Examples G 1 Appendix REVISION iip seduces rior x exeo H 1 LIL liio P Warranty 1 Service Policy Warranty 3 EU Warranty 4 Tis OX dett ande Index 1 o M Index 3 vi Figure 1 1 Figure 1 2 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 2 17 Figure 3 1 Figure 3 2 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure G 1 Figure G 2 Figure G 3 Figure G 4 Figure G 5 List of Illustrations ML Trim Master Mode 00000 1 4 ML Trim Follower 00 1 5 ML Trim Cutout Dimensions and Mounting Guide 2 2 ML Trim General Wiring Guide 2 4 Power Isolated esseeeene 2 7
44. at Equals Follower Setpoint 1 CP 03 value Co e O To find Follower Setpoint 2 CP 04 for Example A Follower E U desired 22 5 Setpoint 2 4 50 Lead E U operation 5 22 5 gal min The Follower Engineering Units gallon per minute at which you want the Follower to operate do not confuse this with the full capacity gal min that the Follower is capable of pumping Divided by 5 gal min The Lead Engineering Units gallon per minute that the Lead is operating at do not confuse this with the full capacity that the Lead is capable of pumping Equals gt Follower Setpoint 2 CP 04 value 18 Table 3 11 Follower Mode Control Parameters Example A e CP 04 Follower Setpoint 2 4 50 The ML Trim will adjust and monitor the speed of the Follower motor to achieve the desired gallons minute This completes the scaling and setpoint information for Example A Example B is discussed in the following section Example B demonstrates how scaling and setpoint Control Parameters are entered for a typical Follower mode of operation that uses a setpoint based on a percentage setpoint The Lead pump delivers 20 gallons minute of ingredient A The Lead motor s is running at a maximum RPM of 1800 and the Lead sensor shaft is equipped with a 60 tooth Ring kit The Follower pump delivers 10 gallons minute of ingredient B The Follower motor is running at a maximum RPM of 1800 and the Follower sensor
45. at Multiplied by 100 Equals 50 Follower Setpoint 1 CP 03 value To find Follower Setpoint 2 CP 04 for Example B Follower E U desired Setpoint 2 z x 100 Lead E U operation 7 gal min The Follower Engineering Units gallons minute of ingredient B at which you want the Follower to operate do not confuse this with the full capacity that the Follower is capable of pumping Divided by 10 gal min The Lead Engineering Units gallons minute of ingredient A that the Lead is operating at do not confuse this with the full capacity that the Lead is capable of operating at Multiplied by 100 Equals 70 Follower Setpoint 2 CP 04 value Table 3 12 Follower Mode Control Parameters Example B Emme e CP 04 Follower Setpoint 2 70 The ML Trim will adjust and monitor the speed of the motors to achieve the desired gallons minute That completes the scaling and setpoint information for Example B After the Control Parameters for the Scaling and for the Follower setpoint have been entered you can enter the Control Parameters for the Acceleration Deceleration of the Follower mode The Control Parameters for Acceleration Deceleration are identical for both the Master and the Follower modes of operations Acceleration Deceleration is discussed in Operation Control Parameters Acceleration Deceleration page 3 26 21 22 Inverse Master Mode The Inverse Master Mode is a variation of the Master Mode The Inv
46. ation MP 44 is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update 44 MP 45 SCALED REFERENCE The Scaled Reference MP 45 is the scaled setpoint number converted to hertz It is the calculated value that is input to the Acceleration Deceleration routine This parameter may display numbers that are larger than 9999 These larger values are displayed with two decimal places For example 10 000 hertz is displayed as 10 00 MP 46 RAMPED REFERENCE The Ramped Reference MP 46 is the calculated output of the Acceleration Deceleration routine in hertz It is the setpoint input to the PID compensation routine This parameter may display numbers that are larger than 9999 These larger values are displayed with two decimal places For example 10 000 hertz is displayed as 10 00 MP 47 SPEED COMMAND OUTPUT The Speed Command Output MP 47 displays the level of calibrated full scale analog output to the motor J2 pin 1 Speed Command Output is displayed as a percentage 100 represents 100 of the calibrated full scale analog output MP 48 TRIM OUTPUT The Trim Output MP 48 is the calculated output of the PID Compensation routine The Trim Output MP 48 added to the Feedforward equals the Speed Command Output MP 47 The Trim Output is represented in DAC Digital to Analog Converter bits where 4096 equals 100 output 2048 equals 50 output etc Status Monitoring Thes
47. ation PID software are not involved in the Direct mode The Direct mode is used in conjunction with the Run and Stop controls See Appendix C CP 61 See Appendix C CP 06 Tests the LED Display Panel Segments Drive Enable Drive Enable activates the motor drive based on the Ramped Reference MP 46 and the feedback The Ramped Reference is the calculated setpoint that is output from the Acceleration Deceleration routine See Appendix C CP 74 Engineering Units E U Master Engineering Units are the units of measure that your system operates at such as RPMs gallons per hour feet per minute Follower Engineering Units is the number that will represent the setpoint when the Lead and Follower are operating at maximum capacity See Appendix C CP 20 and CP 21 EEPROM The EEPROM is where the default Control Parameters are stored This is not to be confused with the PROM chip which is the software for the ML Trim F Stop One of four operating states F Stop brings the ML Trim s speed command analog output to an immediate Zero F Stop has priority over the other operating states Follower Mode A complex multi drive system The scaling format allows the operator to enter the setpoint as either a ratio or percentage The ML Trim compares the setpoint ratio or percentage to the Follower sensor shaft feedback and Lead sensor shaft to calculate any speed error When the ML Trim finds speed error the control algorithm adjusts the Sp
48. aul service at nominal charges to support that OEM Users of Contrex Inc products that were acquired as components of larger systems may buy service or spare parts directly from Contrex Inc at standard prices but they must appeal through the OEM for warranty service If Contrex Inc encounters trouble in the field which appears to be the result of fault or inadequacy of the system Contrex Inc reserves the right to recover service charges from the party that authorized the service activity Warranty 3 WARRANTY Contrex Inc guarantees this device against defects in workmanship and materials for a period of one 1 year from the date of purchase Any parts or components that fail during the warranty period will be replaced or repaired without charge This guarantee is void if the device has been damaged by improper installation or operation tampering careless handling or accident When a device fails to function in accordance with standards set forth in the instruction manual the purchaser should contact an authorized representative of Contrex Inc 8900 Zachary Lane North Maple Grove Minnesota 55369 Whether repairs will take place in the field or at the factory will be solely the prerogative of Contrex Inc If inspection reveals defects that are caused by faulty materials or workmanship Contrex Inc reserves the right to either replace the device or rebuild the device using new or refurbished warranted
49. computer through a RS485 Serial Communications Interface This interface allows the host computer to perform remote computer parameter entry status or performance monitoring and remote control of the ML Trim Active Scaling Format Keypad Error Alarm Status Control State Appendices Appendix A ML Trim Specifications Appendix B Formulas Appendix C Parameter Summary Numeric Quick Reference Appendix D Control Parameter Reference Appendix E Monitor Parameter Reference Appendix F Fax Cover Sheet Appendix G Wiring Diagram Examples Appendix H Revision Log APPENDIX A Accuracy Response Tuning Scaling Formats Setpoints Engineering Units Accel Decel Frequency Inputs Control Inputs Caution ML TRIM SPECIFICATIONS 0196 Set Speed 10 millisecond control loop update Separately adjustable Gain Integral and Derivative parameters for stability and response Direct Direct set of Speed Command Out analog Master Absolute Setpoint entry Follower Ratio Setpoint calculation Inverse Master Absolute Inverse Setpoint entry Inverse Follower Inverse Ratio Setpoint calculation Six Total 2 Master 2 Follower 1 Direct 1 Jog Engineering Unit Setpoint and Display 0 to 600 0 seconds 74HC14 Schmitt Trigger Vin MAX 24 VDC Vin LOW 1 0 VDC Logic Low Vin HIGH 3 5 VDC Logic High 0 30 KHz Feedback amp Lead 4 99 Pullup to 5V Optically Isolate
50. cter will always be 0 Character 12 ETX The return message is always terminated with the ASCII ETX character 61 Data Inquiry Use the Data Inquiry to request the current value for Parameters i e Control Parameters or Monitor Parameters Table 3 33 Data Inquiry Host Transmission ner 2 9 im DEV DEV 2 MSG PAR 4 PAR DATA DATA DATA DATA DATA DESC STX 10s 15 TYPE 10s is 10005 1005 10s 1s FORM je E EORR The following is a description of the Data Inquiry Host Transmission Characters Character 1 STX This is the first character in the character string None of the other characters will be recognized without this character prefix Always use the ASCII STX character it enables the ML Trims receive buffer Characters 2 3 Device These characters are the access address of the ML Trim This number identifies individual ML Trims on a mutltidrop system The ML Trim will accept data only if this number matches the ML Trim s address CP 70 with the exception of a 00 address The 00 address is universally accepted by all ML Trims that are on the RS485 Serial Communications Interface Character 4 Message Type This character should always be 2 Characters 5 6 Parameter Number This is the Control Parameter code i e enter 16 for CP 16 Characters 7 through 10 DATA These characters should al
51. d 74HC14 Schmitt Trigger Vin MAX 24 VDC Vin LOW 1 0 VDC Logic Low Vin HIGH gt 3 5 VDC Logic High 4 99 Pullup to 5V Optically Isolated Run R Stop F Stop Jog Master Follower Setpoint Select Do not exceed 5VDC on the I O Power Input J5 pins 1 2 or equipment damage will occur A 1 A 2 Status Outputs Speed Command Aux Supply Serial Interface Power Requirements Line Loss Operating Temperature Storage Temperature Humidity Physical Dimensions Faceplate Rating Environment Altitude Weight Open Collector Driver ULN2003 50 VDC max 200 mA continuous 500 mA peak Optically Isolated Drive Enable Alarm 0 to 10 VDC Span Pot Adjustable 5 to 12 VDC Optically Isolated 5VDC 5 150 mA Max non isolated RS485 300 to 9600 Baud Full parameter access and control 115 15 VAC model 3200 1931 230 15 VAC model 3200 1932 50 60 Hz 0 1 Amp 70 mSec ride through 0 to 55 C Int Enclosure 0 to 40 C Ext Enclosure 25 to 70 C 0 to 95 non condensing 4 0 inches height 4 0 inches width 6 0 inches depth Interior Panel Nema 4 4X 12 13 IP65 The ML Trim shall be installed in a pollution degree 2 macro environment To 3 300 Feet 1000 meters 49 ounces FORMULAS APPENDIX B Use the following formulas to calculate Speed Control PES J9MO0JIOJ azaan 3 2 rey
52. d Parameter Value Performance Monitoring PROM Chip PROM Test PPR Feedback PPR Lead Glossary 8 Speed Command Output MP 47 Logic Outputs MP 56 Tests the Logic Outputs Speed Command Out J2 pins 1 2 Drive Enable J5 pin 16 18 Alarm J5 pin 17 18 Parameters are divided into two classifications Control Parameters CP and Monitor Parameters MP The numbered code that represents a Parameter Use the Parameter Send to change any of the ML Trim s Control Parameters in Serial Communications Parameter values are pre loaded in the factory however you can modify Control Parameter values with operational data that is unique to your system Tach Deviation Error Scaled Reference Ramped Reference Trim Output The PROM Programmable Read Only Memory chip is the software for the ML Trim This is not to be confused with the EEPROM which is were the default Control Parameters and Monitor Parameters are stored One of the two power up diagnostic routines that the ML Trim automatically performs during every Power Up See Appendix C CP 31 See Appendix C CP 30 Tuning Tuning stabilizes speed error differences between the setpoint and feedback Ring Kits Ring Kits are flange motor mounted sensors that measure the pulses per revolution PPR of the motor shaft R Stop One of four operating states R Stop uses Deceleration Rate CP 17 to decelerate the Speed Command analog output to zero R
53. d in CP 34 Now that your scaling has been established you can enter a value for Master Setpoints 1 and 2 The value that you enter for a setpoint is the Engineering Units E U s that you want to operate your system at The factory default Control Parameters for Master Setpoint 1 and 2 are set at 0 To modify these default parameters refer to Table 3 6 You can toggle between the two setpoints if you have wired the Setpoint Select accordingly Setpoint Select located at J5 pins 13 14 determines which of the two setpoints is active refer to Setpoint Select on page 2 12 If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Table 3 6 Entering Master Setpoint Control Parameters CP Parameter Name Parameter Value Enter the Master Engineering Units value that you want your system to operate at when Setpoint 1 is active Master Setpoint 1 Enter the Master Engineering Units value that you want your system to operate at when Setpoint 2 is active Master Setpoint 2 An example of the Master mode of operation is demonstrated on the following page 11 Master Mode Example The following example demonstrates how scaling and setpoint Control Parameters are entered for a typical Master mode of operation A pump delivers 15 gallons minute when the motor runs at a maximum RPM of 1725 The motor shaft is equipped with a 30 tooth Ring kit The Master Engineering Units are gall
54. dd ZH be d9 pea xen d9 X v d9 jurodies OJO 4 N I Pe du xen du be d9 X v d9 w odjes T 1 ta yoeqpes peo be d9 cao IW qd 8MOJJOFJ 5n 3 J9MO 04 v d9 tujodies AGOW H3MOT1OJ 09 Je 049 N a 2 Rees xen du be d9 X sen UIOdJIS z 1 40 eJauan XENIA JH be d9 xXoeqpee4J v d9 yoeqpes4 0497 eran odes 49 Seyy 02 49 na iseihurodies 24 AGOW H31SVIN ZH je19U9H NOTES APPENDIX C PARAMETER SUMMARY NUMERIC QUICK REFERENCE CP 01 MASTER SETPOINT 1 The Engineering Units value that you want your system to operate at when Master Setpoint 1 CP 01 is active If the Master Setpoint is equal to the Master Engineering Units CP 20 then the system will run at its maximum RPMs or Max RPM Feedback CP 34 The factory default Master Setpoint Control Parameters are set at 0 CP 02 MASTER SETPOINT 2 The Engineering Units value that you want your system to operate at when Master Setpoint 2 CP 02 is active If the Master Setpoint is equal to the Master Engineering Units CP 20 then the syst
55. death Line Neut Armature Contactor 235 e om ES 5V 9 9 XR COM AUX DI 5V Ext 4D COM Pwr Supply mos 2 gt e USAID Jr Feedback ic O 25 5 FDBK_FQ Freq MAX_SPD 582 z COM KJ LE RUN Run Speed a 3 JOG kj m x DRV_COM pom COM 235 do R STOP ER R Stop as m F STOP zm F Stop MST FOL m SETPT COM lt ap 2 EN g 5 ALARM O COM Figure G 2 Relay Start Stop Wiring Connections DANGER This diagram is for conceptual purposes only Use safety equipment Make wiring connections carefully Incorrect use of equipment or connections can cause injury or death Command K R 1 2 Line INC O MAX_SPD J2 SNI 871 S OL SIVNINYAL f N31H9LL NINO 9 92 09 HOS OL 3ZIS 3UIM 19313S 34IM H3ddOO ASN DIGITAL DIGITAL OUTPUTS Armature Contactor COM AUX DI COM LEAD FQ FDBK FQ COM RUN JoG COM R STOP F STOP COM MST FOL SETPT COM V DO EN ALARM COM Figure G 3 Start Stop for Regen with Armature Contactor 5V Ext Pwr Supply Feedback Freq Run Jog R Stop F Stop Neut DANGER This diagram is for conceptual purposes only Use safety equipment Make wiring connections carefully Incorrect use of equip
56. e MPs monitor the status of the ML Trim s modes of operation and operating states MP 50 ACTIVE SCALING MODE The digit that displays a number 1 is the Active Scaling Mode MP 50 In the example below Master Mode is the active Scaling mode Code Direct Mode Master Mode Follower Mode Inverse MP 51 KEYPAD ERROR If a Control Parameter entry has been rejected Keypad Errors MP 51 will ascertain the reason that it was rejected The digit that displays a number 1 is the error In the example below Above Maximum Allowed Value is the error Code Invalid Code Parameter Above Maximum Allowed Value Below Minimum Allowed Value Entry Timeout or Keypad Lockout 46 MP 52 ALARM STATUS The digit that displays a number 1 is the active Alarm In the example below High Speed Alarm is the active alarm Code Low Speed Alarm High Speed Alarm Ramped Error Scaled Error MP 53 CONTROL STATE The digit that displays a number 1 is the active control state of the ML Trim In the example below Run is the active control state Code MP 57 EEPROM STATUS The Control Parameters are stored in the EEPROM memory chip EEPROM Status MP 57 displays the status of the EEPROM memory chip The number 0 indicates no failure The number 1 indicates a write verify error In the event of an error call Technical Support at 612 424 7800 or 1 800 342 4411 MP 59 FREQUENCY OVER FLOW COU
57. e Master or the Follower mode Alarms are discussed in the following section Parameter Value With Integral CP 66 set to O reduce the Gain CP 65 until the system becomes unstable then increase it slightly until the system stabilizes Reduced values will increase Gain To verify the stability of the speed changes you can access Tach through either the Tach key or the Monitor Parameter for Tach MP 40 While switching between the high and low setpoints decrease the Integral s default value of 2000 until the speed error is reduced within an acceptable time frame To verify the stability of the speed changes you can access Tach through either the tach key or the Monitor Parameter for Tach MP 40 The Derivative should not be adjusted in most systems However sometimes in the larger inertia systems you can improve performance by lowering the Derivative term to the point of instability and then increasing it incrementally until the system stabilizes Alarms The Control Parameters for Alarms are identical for both the Master and the Follower modes of operations By entering values in the Control Parameters for the Alarms CP 12 CP 13 CP 14 CP 15 you can establish circumstances under which the ML Trim will alert you to potential operating problems The Alarm Format CP 10 can be set to activate at any combination of low speed high speed ramped error or scaled error conditions The alarm output can be w
58. e maximum revolutions per minute of 2000 RPM then the twist length lay is at its minimum of 2 0 inches The Follower motor uses a 1200 PPR encoder and the Lead motor shaft is equipped with a 60 tooth ring kit Follower Setpoint 1 is setup for the minimum twist lay of 2 0 inches Follower Setpoint 2 is setup for a twist lay of 5 0 inches Table 3 18 shows the scaling Control Parameters that would be entered in the ML Trim for this example Table 3 18 Inverse Follower Mode Control Parameters Example Parameter Name Parameter Value CP 31 PPR Feedback 1200 After the Scaling and the Follower Setpoints for your system have been entered you can enter the Acceleration Deceleration Control Parameters for the Inverse Follower mode The Acceleration Deceleration Control Parameters are identical for both the Inverse Master and the Inverse Follower modes of operations Acceleration Deceleration is discussed in the following section 25 26 Acceleration Deceleration Acceleration Deceleration CP 16 and CP 17 control the rate of speed change in response to setpoint changes These parameters apply to both the Master and Follower modes of operation The ML Trim comes factory pre loaded with default Control Parameters for Acceleration Deceleration Generally these default settings are suitable for most applications and do not require modification The factory default Control Parameters for Timing are found in Table 3 19 To modify these d
59. ect and Master Follower Control Parameters Control Parameters allow you to enter data that is unique to your system e g encoder resolution Lead to Follower ratios and modify the ML Trim s operation for your specific application e g maximum RPMs setpoints acceleration deceleration ramp rates There are Control Parameters for Direct mode Master stand alone mode Glossary 3 Data Inquiry Deceleration Time Dedicated Keys Derivative Digital Motor Controller Direct Mode Direct Enable Direct Setpoint Display Test Glossary 4 the Follower mode Acceleration Deceleration Tuning Alarms and Jog The ML Trim comes factory pre loaded with a complete set of default Control Parameters Use the Data Inquiry to request the current value for Parameters i e Control Parameters or Monitor Param eters in serial communications See Appendix C CP 17 The Setpoint key and the Tach key are shortcut keys The Setpoint key accesses the active setpoint variable directly and the Tach key accesses the tach variable directly rather than manually entering the Code Parameter See Appendix C CP 67 A precision motor controller that uses digital compensation technology In the Direct mode of operation the analog Speed Com mand from the ML Trim that is connected to the motor drive can be set directly Direct mode is an open loop mode of operation Scaling Acceleration Deceleration and closed loop compens
60. ed error adjust the Gain CP 65 until the system stabilizes In systems that require greater accuracy it may be necessary to adjust the Integral CP 66 to reduce any remaining speed error In systems with low inertia the speed error will be reduced more quickly if you enter low values in CP 66 An entry that is too low however can create instability or overshoot the setpoint before reaching the correct value Generally use larger entries for CP 66 on systems with a large inertia Sometimes performance can be improved in systems with a large inertia by lowering the Derivative CP 67 The ML Trim comes factory pre loaded with default Control Parameters for Tuning These default settings are suitable for most applications and do not require modification The factory preset default tuning Control Parameters are found in Table 3 21 To modify these default parameters refer to Table 3 22 If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Table 3 21 Default Master or Follower Tuning Control Parameters CP Parameter Name Parameter Value CP 65 Gain Proportional 9000 CP 67 Derivative 9000 28 Table 3 22 Entering Master Follower Tuning Control Parameters Parameter Name Parameter Value Name CP 65 Gain Proportional CP 66 Integral After the Control Parameters for Tuning have been entered you can enter the Control Parameters for the Alarms for either th
61. ed value that is input to the Acceleration Deceleration routine This parameter may display numbers that are larger than 9999 These larger values are displayed with two decimal places For example 10 000 hertz is displayed as 10 00 MP 46 RAMPED REFERENCE The Ramped Reference MP 46 is the calculated output of the Acceleration Deceleration routine in hertz It is the setpoint input to the Pl compensation routine This parameter may display numbers that are larger than 9999 These larger values are displayed with two decimal places For example 10 000 hertz is displayed as 10 00 MP 47 SPEED COMMAND OUTPUT The Speed Command Output MP 47 displays the level of calibrated full scale analog output to the motor drive J2 pin 1 Speed Command output is displayed as a percentage 100 represents 100 of the calibrated full scale analog output MP 48 TRIM OUTPUT The Trim Output MP 48 is the calculated output of the PID Compensation routine The Trim Output added to the feedforward equals the Speed Command Output MP 47 The Trim Output MP 48 is represented in DAC Digital to Analog Converter bits for example 4095 equals 10096 output 2048 equals 5096 output MP 50 ACTIVE SCALING MODE Active Scaling Mode MP 50 displays a number 1 to indicate the active scaling mode In the example below Master Mode is the active scaling mode Code Direct Mode Master Mode Follower Mode Inverse MP 51 KEYPAD ERROR If a
62. eed Command analog output and reduces the error to zero Gain See Appendix C CP 65 Hardwired Inputs that are wire shorted rather than using push buttons or switches Input Monitoring Lead Frequency MP 41 Feedback Frequency MP 43 Logic Inputs Group A MP 54 Logic Inputs Group B MP 55 Glossary 5 Input Test Inputs Integral Jog Keypad Test LED Display Logic Inputs Glossary 6 Tests the Logic Inputs AC Power J3 pins 1 2 3 Power J5 pins 1 2 Lead Frequency J5 pins 3 5 Feedback Frequency J5 pins 4 5 Run J5 pins 6 8 Jog J5 pins 7 8 R Stop J5 pins 9 11 F Stop J5 pins 10 11 Master or Follower J5 pins 12 14 Setpoint Select J5 pins 13 14 See Appendix C CP 66 One of four operating states Jog increases the RPMs at the acceleration rate that is specified in Acceleration Time CP 16 until the Jog Setpoint CP 05 is achieved When Jog is terminated there is no deceleration time the drive motor comes to an immediate stop Tests the Keypad The two digit Parameter Code is displayed on the left LED Display The Parameter Code s value is displayed on the right LED display This value can be up to four digits F Stop R Stop Run Jog Setpoint Select Master Follower Master Mode A stand alone control of a single motor The scaling format allows the operator to enter a setpoint in Engineering Units The ML Trim compares the sensor shaft feedback to t
63. efault parameters refer to Table 3 20 If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Table 3 19 Default Master or Follower Acceleration Deceleration Control Parameters CP Parameter Name Parameter Value 5 0 Deceleration Time Table 3 20 Entering Master or Follower Acceleration Deceleration Control Parameters CP Parameter Name Parameter Value Acceleration Time Enter the desired number of seconds to increase the motor speed from 0 to 2000 RPMs Deceleration Time Enter the desired number of seconds to decrease the motor speed from 2000 to 0 RPMs After the Control Parameters for Acceleration Deceleration have been entered you can enter the Control Parameters for Tuning either the Master or the Follower mode The tuning Control Parameters are identical for both the Master and the Follower modes of operations Tuning is discussed in the following section Tuning If your system is unstable or the speed error is unacceptable tuning stabilizes speed error differences between the setpoint and feedback You can achieve a stable system using conservative tuning Control Parameter values however the speed error may be unacceptable On the other hand aggressive tuning Control Parameter values may cause the system to become unstable The goal is to reduce the speed error to the level that you want yet maintain the system s stability To achieve an acceptable level of spe
64. em will run at its maximum RPMs or Max RPM Feedback CP 34 The factory default Master Setpoint Control Parameters are set at 0 CP 03 FOLLOWER SETPOINT 1 The Engineering Units value that you want your system to operate at when Follower Setpoint 1 CP 03 is active The Follower setpoint values are the ratio of Follower speed to Lead speed CP 04 FOLLOWER SETPOINT 2 The Engineering Units value that you want your system to operate at when Follower Setpoint 2 CP 04 is active The Follower setpoint values are the ratio of Follower speed to Lead speed CP 05 JOG SETPOINT In Jog Setpoint CP 05 enter the RPM at which you want your system to operate when it is in Jog Jog increases the RPMs at the acceleration rate that you specified in Acceleration Time CP 16 until the Jog Setpoint CP 05 is achieved When Jog is terminated there is no deceleration time the drive comes to an immediate stop CP 06 DIRECT SETPOINT Use the Direct Setpoint CP 06 to set the drive output that is used when the ML Trim is in the Direct Mode of operation Direct mode is an open loop mode of operation Scaling Acceleration Deceleration and closed loop compensation PID software are not involved in the Direct mode The Direct mode is used in conjunction with the Run and Stop controls CP 10 ALARM FORMAT By entering alarm Control Parameters you can establish circumstances under which the ML Trim will alert you to potential operating problems The
65. en Contrex Technical Support Fax Number 1 763 424 8734 From Name Ext Company Telephone Fax We have ML Trim s that are used for Serial Communication Hookup Yes No Brief Description of the Problem We are transmitting pages including this Cover Sheet a copy of Appendix D with the User Record completed a sketch of the system that the ML Trim is integrated with Please turn the page to record any CPs that you have changed from the default value gt Please record the Control Parameters that you have changed from the default value Code Description User Code Description Record CP 01 Master Setpoint __ _______ 31 PPR Feedback CP 02 MasterSetpoint2 CP 33 MaxRPMLead CP 03 FollowerSetpoint 1 CP 34 RPM Feedback CP 04 Follower Setpoint2 CP 61 DirectEnable CP 62 Inverse Scaling CP 05 Jog Setpoint It CP 06 DirectSetpoint ____ CP 64 Display Mode Follower CP 10_ AlarmFormat CP65 Gan CP 12 LowAlarm ____ 66 13 HighAlam 67 Derivative on Time LCP 20 Master Eng Units CP 74 Drive Enable Loge P1 Follower Eng Units Keypad Lockout CP 14 Ramped Error Alarm CP 70 Device Address Please record what the relevant Monitor Parameters display when the problem occurs Code Description Displayed Code Description Displayed
66. en the ML Trim is in Jog To activate Run Short the F Stop and R Stop inputs to common Open the Jog input Short the Run input to common Run is latched and does not need to be maintained to remain active RUN JOG COMMON R STOP F STOP COMMON Close Momentarily Jog has the least operating priority Jog ramps to the Jog Setpoint CP 05 using the Acceleration Time CP 16 When Jog is terminated the ML Trim brings the Speed Command output to an immediate Zero Unlike the other inputs Jog is not latched and must be sustained to remain active To activate Jog Short the F Stop and R Stop inputs to common Open the Run input Short the Jog input to common Jog must be sustained to remain active RUN JOG COMMON R STOP F STOP COMMON Maintain Closed Logic Output Drive Enable activates the motor drive based on the Ramped Reference MP 46 and the feedback The Ramped Reference MP 46 is the calculated setpoint that is output from the Acceleration Deceleration routine Drive Enable Logic CP 74 determines which conditions of the Ramped Reference MP 46 and feedback will control the Drive Enable output The factory defaults for Drive Enable Logic CP 74 is found in Table 3 27 To modify this default parameter refer to Table 3 28 If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Table 3 27 Default Drive Enable Logic Control Param
67. enter values in the Follower Setpoints CP 03 and CP 04 that represent the E U at which you want the system to operate The higher the setpoint value the lower the Follower to Lead ratio speed The ML Trim comes factory pre loaded with the default Control Parameters for the standard Follower Mode These default settings are not suitable for Inverse applications and require modification The factory default Control Parameters for the standard Follower Mode are found in Table 3 16 To modify these default parameters refer to Table 3 17 If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Table 3 16 Default Inverse Follower Control Parameters CP Parameter Name Parameter Value Inverse Scaling 1 Standard Scaling Follower E U Table 3 17 Entering Inverse Follower Control Parameters CP Parameter Name Parameter Value Inverse Scaling Enter 2 for Inverse Scaling Follower E U Enter the minimum Engineering Units if the system were to operate at the Max RPM Lead CP 33 and the Max RPM Feedback CP 34 Inverse Follower Mode Example The Inverse Follower Mode Example demonstrates how the scaling and setpoint Control Parameters are entered for a typical Inverse Follower mode of operation In a wire machine twisiting application the Follower twists the wire as the Lead pulls the wire When the Follower is at the maximum revolutions per minute of 1800 RPM and the Lead is at th
68. er string Table 3 32 Control Command Send ML Trim Response E e ee E A EN DEV DEV ERROR PAR PAR DATA DATA DATA DATA DATA DESC STX 10s 1s 10s 15 1000s 1005 10s 1s FORM EA ases The following is a description of the Control Command Send ML Trim Response Characters Character 1 STX This is the first character in the character string Characters 2 3 Device This is the two character access address for the ML Trim Character 4 Error Code If there are errors in the transmission that the ML Trim receives from the host computer the Error Code will display them Use Table 3 35 page 3 66 to convert the ASCII code to binary The binary code can be decoded as follows Bit 7 Always 0 Bit 6 Always 1 Bit 5 1 Data was out of minimum maximum range Bit 4 1 Checksum or Decimal Point Error Invalid Parameter Code Bit 3 1 Receive buffer filled before ETX received or Message Format Error Bit 2 1 Invalid Parameter Data Bit 1 1 Parity Error Bit 0 1 Always 0 Note The ML Trim will only accept data if there are no errors The ASCII error code Binary code 1000000 indicates that the Host Transmission contains no errors Characters 5 6 Parameter Number These characters will always be 0 Characters 7 through 10 DATA These characters will always be 0 Character 11 Data Format This chara
69. erse Master Mode has an inverted setpoint If you increase the value of the setpoint CP 01 or CP 02 then the motor speed will decrease Inverse Mode setpoints generally use engineering units of time With the Inverse Scaling CP 62 set to 2 enter values in the Master Setpoints CP 01 and CP 02 that represent the E U at which you want the system to operate The higher the setpoint value the slower the motor speed Inversely the lower the setpoint value the higher the motor speed The ML Trim comes factory pre loaded with the default Control Parameters for the standard Master Mode These default settings are not suitable for Inverse applications and require modification The factory default Control Parameters for the standard Master Mode are found in Table 3 13 To modify these default parameters refer to Table 3 14 If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Table 3 13 Default Inverse Master Control Parameters CP Parameter Name Parameter Value Inverse Scaling 1 Standard Scaling Master E U Table 3 14 Entering Inverse Master Control Parameters Parameter Name Parameter Value Inverse Scaling Enter 2 for Inverse Scaling Master E U Enter the minimum Master Engineering Units value if the system were to operate at the maximum RPMs entered in CP 34 Inverse Master Mode Example The Inverse Master Mode Example demonstrates how scaling and setpo
70. ess to the Parameters Control Parameters and Monitor Parameters by entering the Parameter Code You can also use the keypad to change the value of a Control Parameter The keypad has keys for Code Select Enter Clear and Scroll Up Down It also has numeric keys and two dedicated keys Setpoint and Tach The LED display is the above the keys Figure 3 1 displays the location of the keys and LED display on the keypad Table 3 1 demonstrates basic keypad entry The keypad functions as follows Code Select Key Numeric Keys Dedicated Keys Scroll Up Down Keys LED Display Press this key prior to entering a Parameter Code either a Control Parameter or a Monitor Parameter Use the numeric keys to enter a Parameter Code for either a Control Parameter CP or a Monitor Parameter MP or to enter a value for a Control Parameter Use the Enter key after each entry Use the Clear key to delete your entry The Setpoint key and the Tach key are shortcut keys The Setpoint key accesses the active setpoint variable directly and the Tach key accesses the tach variable directly rather than manually entering the Code Parameter These keys will change the active setpoint value even if that setpoint is not displayed in the LED Display Each time you press the scroll up key the active setpoint will increase by one increment Each time you press the scroll down key the active setpoint value will decrease by one increment It will also automat
71. eter CP Parameter Name Parameter Value Table 3 28 Entering Drive Enable Logic Control Parameter CP Parameter Name Parameter Value CP 74 Drive Enable Logic Enter 0 in CP 74 to deactivate the Drive Enable output output high when the Ramped Reference is zero and activate the Drive Enable output output low when the Ramped Reference is not zero Enter 1 in CP 74 to deactivate the Drive Enable output when both the Ramped Reference and the feedback are zero and activate the Drive Enable output when the Ramped Reference is not zero 38 NOTES MONITOR PARAMETERS Parameters are divided into two classifications Control Parameters CP and Monitor Parameters MP The numbered code that represents the Parameter is the Parameter Code The operational data is the Parameter s value Control Parameter 05 50 Parameters Monitor Parameter 40 200 arbitrary Parameter Code Parameter Value This section is about Monitor Parameters Control Parameters are explained in Operation Control Parameters page 3 7 The ML Trim has a number of Monitor Parameters MPs that monitor the performance of the ML Trim and your system troubleshoot for problems and confirm the wiring and tuning MPs can be accessed at any time during the ML Trim s operation including during Run Jog R Stop and F Stop Note Monitor Parameters are status indicators only you can not directly affect a MP There are four ca
72. g When the ML Trim is powered up it defaults to R Stop If either Run or Jog have been hardwired the ML Trim will operate in either Run or Jog instead of R Stop Run is hardwired by shorting Run R Stop and F Stop to common Jog is hardwired by shorting Jog R Stop and F Stop to common The motor drive is activated by the Drive Enable digital output The sections that follow demonstrate how to use the digital inputs and the Drive Enable output Caution Do not use the AC line power to start or stop the system Use the Digital Inputs to start or stop the system Logic Inputs F Stop has priority over the other operating states F Stop brings the ML Trim s Speed Command output to an immediate Zero To activate F Stop Open the F Stop Input F Stop is latched and does not need to be maintained to remain active F STOP COMMON Open Momentarily R Stop has the second highest operating priority R Stop decelerates the Speed Command output to Zero using the Deceleration Time CP 17 To activate R Stop Short the F Stop input to common Open the R Stop input R Stop is latched and does not need to be maintained to remain active R STOP R STOP F STOP COMMON Open Momentarily Run has the third highest operating priority Run ramps to the scaled setpoint speed using the Acceleration Time CP 16 Run can be activated when the ML Trim is in R Stop or F Stop however Run cannot be activated wh
73. g Units e g Follower to Lead ratio or percentage of RPMs gallons per minute feet per minute The Follower Engineering Units that you want the system to operate at are entered into the two available Follower Setpoints CP 03 and CP 04 However before the ML Trim can determine how to operate at these setpoints you must enter Scaling Control Parameters into the ML Trim Scaling is a convenient method for translating the relationship of the Lead and Follower motor RPMs into Follower Engineering Units Scaling Control Parameters give the ML Trim the following information Max RPM Lead CP 33 Measured at the Lead sensor shaft this number is the maximum RPMs at which the Lead will operate in your system Max RPM Feedback CP 34 Measured at the sensor shaft this number is the maximum RPMs at which you want the follower to operate when the Lead is operating at its maximum RPMs This number is identical to the maximum operating speed that you set in step 7 of the calibration procedure on page 2 20 PPR Lead CP 30 The number of gear teeth or number of encoder lines on the Lead sensor per revolution pulses per revolution PPR Feedback CP 31 The number of gear teeth or number of encoder lines on the Follower feedback sensor per revolution Follower Engineering Units CP 21 Enter a number that will represent the setpoint Engineering Units when the Lead and Follower are operating at their maximum RPMs This number is usually either the
74. g Units page 3 13 C 3 D 1 Follower Mode page 3 13 Glossary 5 Application page 1 5 Example page 3 16 Follower Setpoint 1 page C 1 D 1 Follower Setpoint 2 page C 1 D 1 Formulas page B 1 Frequency Overflow Counter page 3 47 C 10 E 1 G Gain page 3 27 C 11 D 1 Glossary page Glossary 3 H Hardwired page Glossary 5 High Alarm page 3 46 C 2 D 1 Host Computer Interface page 3 49 3 52 Housing the ML Trim page 2 3 How to Enter a Parameter Code page 3 4 Enter a Parameter Value Control Parameter page 3 4 Replace the PROM Chip page 4 16 Use Serial Communications page 3 50 Index 5 Use the Setpoint Key page 3 4 Use the Tach Key page 3 4 Use the Up Down Scroll Keys page 3 4 Power J5 pins 1 2 page 2 7 Input Monitoring page 3 40 Glossary 5 Test page 4 7 Glossary 6 Inputs page Glossary 6 Wiring page 2 7 Installation Calibration page 2 17 Mounting the ML Trim page 2 3 Wiring page 2 5 Integral page 3 27 C 11 D 1 Interface with a Host Computer page 3 49 3 52 Internal Control Structure of the ML Trim page 3 43 Inverse Master Mode page 3 22 3 24 Inverse Scaling page 3 22 3 24 C 11 J J2 pins 1 2 Speed Command Out page 2 13 J3 pins 1 2 3 AC Power page 2 8 pins 1 2 I O Power page 2 7 J5 pin 16 Drive Enable page 2 13 J5 pin 17 Alarm page 2 14 J5 pins 10 11 F Stop page 2 11 J5 pins 12 14 Master or Follower page 2 11 J5 pins 13 14 Setpoint Se
75. hat increments each time the frequency input to the ML Trim causes an overflow To reset the counter to 0 press the Clear key CP 61 DIRECT ENABLE In the Direct mode of operation the Speed Command output from the ML Trim that is connected to the motor drive can be set directly Direct mode is an open loop mode of operation Use Direct Enable CP 61 to either enable or disable the Direct mode Enter 1 to enable the Direct Mode Enter 0 to disable the Direct Mode Code Enabled CP 62 INVERSE SCALING Use Inverse Scaling CP 61 to select either the Standard or the Inverse setpoint scaling format Enter 2 for Inverse Scaling Enter 1 for Standard Scaling Code Inverse Scaling CP 64 DISPLAY MODE FOLLOWER In the Follower mode of operation Display Mode Follower CP 64 determines how the data will display in Tach CP 40 Enter 2 to display the ratio of feedback to lead in E U Follower Enter 1 to display the feedback in E U s Time Master CP 65 GAIN To achieve an acceptable level of speed error adjust Gain CP 65 until the system stabilizes With Integral CP 66 and Derivative CP 67 set to 0 reduce the Gain CP 65 value until the System becomes unstable then increase it slightly until the system stabilizes Reduced values will increase Gain To verify the stability of the speed changes you can access Tach through either the Tach key or the Tach MP 40 CP 66 INTEGRAL In systems that
76. he Logic Inputs Press the UP or DOWN scroll keys until the diagnostic indicator and the number 4 are visible on the left side of the LED display Press Enter to start the test The LED display will be blank unless an input has been shorted If an input has been shorted it s number will display For example if the number three appears in the display then R Stop has been shorted To test an input short that input and open all of the other inputs Input Closure Display RUN J5 6 JOG 5 7 R STOP J5 9 F STOP J5 10 MASTER FOLLOWER 45 12 SETPOINT SELECT J5 13 Press CLEAR to exit the test Press CODE SELECT only if you want to exit diagnostics Output Test 5 To Test the Logic Outputs Press the UP or DOWN scroll keys until the diagnostic indicator and the number 5 are visible on the left side of the LED display Only the diagnostic indicator and the number 5 will be visible on the LED display during this test To run this test connect the outputs to a pull up resistor and either a meter or LED or connect the outputs to a relay and either lights or sound Press Enter to start the test Press keys 1 2 to activate the outputs Press To Activate 1 Drive Enable 2 Alarm Press Clear to exit the test Press CODE SELECT only if you want to exit diagnostics TROUBLESHOOTING This section contains four troubleshooting flowcharts to help
77. he scaled setpoint and calculates any speed error When the ML Trim finds speed error the control algorithm adjusts the Speed Command analog output and reduces the error to zero Master Setpoints See Appendix C CP 01 and CP 02 Max RPM Feedback See Appendix C CP 34 Max RPM Lead See Appendix C CP 33 Mode of Operation The scaling method that is used to operate your system e g Direct mode Master mode Follower mode Inverse Master mode or Inverse Follower mode Monitor Parameters Monitor Parameters MPs monitor the performance of the ML Trim and the system which the ML Trim is controlling Monitor Parameters also confirm the wiring and the tuning as well as assist with troubleshooting MPs can be ac cessed at any time during the ML Trim s operation including during Run Jog R Stop and F Stop There are four categories of Monitor Parameters Input Monitoring Output Monitoring Performance Monitoring and Status Monitoring Numeric Keys Use the numeric keys to enter a Parameter Code for either a Control Parameter CP or a Monitor Parameter MP or to enter a value for a Control Parameter Use the Enter key after each entry Use the Clear key to delete your entry Open Loop A system that is controlled without feedback Operating State The systems status within a mode of operation such as Run R Stop F Stop or Jog Glossary 7 Output Monitoring Output Test Outputs Parameters Parameter Code Parameter Sen
78. here are six different baud rates data rates for the ML Trim Enter the number for the required function in Baud Rate CP 71 as listed below 1 300 Baud 2 600 Baud 3 1200 Baud 4 2400 Baud 5 4800 Baud 6 9600 Baud CP 72 CHARACTER FORMAT The ML Trim uses three different character formats Enter the number for the required format in Character Format CP 72 as listed below 1 8 Data Bits No Parity One Stop Bit 2 7 Data Bits Even Parity One Stop Bit 3 8 Data Bits No Parity Two Stop Bit CP 73 CONTROL MASK The Serial Communications can control some of the logic input functions Enter the number for the required functions in Control Mask CP 73 as listed below 0 F Stop only 1 F Stop Run R Stop 2 F Stop Master Follower Setpoint Select 3 All of the above CP 74 DRIVE ENABLE LOGIC Drive Enable Logic CP 74 determines which conditions of the Ramped Reference MP 46 and the feedback will control the Drive Enable digital output Enter 0 to deactivate the Drive Enable digital output output high when the Ramped Reference is zero and activate the Drive Enable digital output output low when the Ramped Reference is not zero Enter 1 to deactivate the Drive Enable digital output when both the Ramped Reference and the feedback are zero and activate the Drive Enable digital output when the Ramped Reference is not zero CP 98 KEYPAD LOCKOUT Keypad Lockout CP 98 displays the present sta
79. hertz pulses per second Lead Frequency MP 41 is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update Because Lead Frequency MP 41 is not averaged or filtered and because of sensor irregularities it may appear less stable than Tach MP 40 Numbers that are larger than 9999 are displayed with two decimal places For example 10 000 hertz is displayed like the figure in Feedback Frequency MP 43 MP 43 FEEDBACK FREQUENCY The Feedback Frequency MP 43 displays the frequency of the Feedback Frequency Input J5 pin 4 in units of hertz pulses per second Feedback Frequency MP 43 is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update Because Feedback Frequency MP 43 is not averaged or filtered and because of sensor irregularities it may appear less stable than Tach MP 40 Numbers that are larger than 9999 are displayed with two decimal places For example 10 000 hertz is displayed as follows Two Decimal Places MP 44 DEVIATION ERROR Deviation MP 44 displays the difference between the Ramped Reference MP 46 and the Feedback Frequency MP 43 measured in units of hertz pulses per second Deviation is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update MP 45 SCALED REFERENCE The Scaled Reference MP 45 is the scaled setpoint number converted to hertz It is the calculat
80. ically scroll through the increments or decrements if you hold the key down The two digit Parameter Code is displayed on the left LED Display The Parameter Code s value is displayed on the right LED display This value can be up to four digits Table 3 1 Basic Keypad Entry To Enter a Parameter Code Press Code Select Enter a Parameter Code For a Control Parameter or Monitor Parameter Press Enter within 15 seconds The Parameter Code and it s current value are displayed on the LED display The Parameter Code decimal point is illuminated To Enter a Parameter Value Follow the steps to enter a Parameter Code For Control Parameters only Monitor Enter a new value Use the numeric keys Parameters can not be changed Press Enter within 15 seconds manually The Parameter Code decimal point turns Off To Use the Tach Key Press Tach The scaled Engineering Unit Feedback is displayed To Use the Setpoint Key Press Setpoint The active setpoint and its value are displayed To Use the Up Down Press the Up scroll key to increase the active setpoint value Scroll Keys Press the Down scroll key to decrease the active setpoint value Parameter Code Parameter Value 2 digits up to 4 digits Led Display Code Select Key nn Dedicated Keys en Numeric Keys Up Down id Scroll Keys Clear Key Figure 3 1 The ML Trim Front Panel KEYPAD LOCKOUT Keypad Lockout CP 9
81. int Control Parameters are entered for a typical Inverse Master mode of operation It takes 10 seconds to move a product through a heat treat oven when the conveyor motor is running at 1500 RPM The conveyor motor shaft is equipped with a 60 tooth ring kit Set Master Setpoint 1 CP 01 so that the product is in the oven for 20 seconds Set Master Setpoint 2 CP 02 so that the product is in the oven for 15 seconds Table 3 15 shows the scaling Control Parameters that would be entered in the ML Trim for this example Table 3 15 Inverse Master Mode Control Parameters Example CP 02 Master Setpoint 2 15 0 After the Scaling and the Master Setpoints for your system have been entered you can enter the Acceleration Deceleration Control Parameters for the Inverse Master mode The Acceleration Deceleration Control Parameters are identical for both the Inverse Master and the Inverse Follower modes of operations Acceleration Deceleration is discussed in Operation Control Parameters Acceleration Deceleration page 3 26 The following section demonstrates how to enter Control Parameters for the Inverse Follower mode of operation 24 Inverse Follower Mode The Inverse Follower Mode is a variation of the Follower Mode The Inverse Follower Mode has an inverted setpoint If you increase the value of the setpoint CP 03 or CP 04 then the ratio of Follower speed to Lead speed will decrease With the Inverse Scaling CP 62 set to 2
82. ions Interface Generally the default settings are suitable for most applications and do not require modification The factory default Control Parameters for Serial Communications Setup are found in Appendix D These default parameters can be modified using the Serial Communications Interface CP 70 DEVICE ADDRESS The ML Trim has a physical address which can be set from 1 to 32 Each individual ML Trim on a multidrop RS485 communications link needs a unique Device Address The address 00 will be globally accepted by all of the ML Trims on a communications link however they will not send a response message back to the host computer when this global address is used CP 71 BAUD RATE There are six different baud rates data rates for the ML Trim Enter the number for the required function as listed below 1 300 Baud 2 600 Baud 3 1200 Baud 4 2400 Baud 5 4800 Baud 6 9600 Baud CP 72 CHARACTER FORMAT The ML Trim uses three different character formats Enter the number for the required format as listed below 1 8 Data Bits No Parity One Stop Bit 2 7 Data Bits Even Parity One Stop Bit 3 8 Data Bits No Parity Two Stop Bits CP 73 CONTROL MASK The Serial Communications can control some of the digital input functions Enter the number for the required functions as listed below 0 F Stop only 1 F Stop Run R Stop 2 F Stop Master Follower Setpoint Select 3 All of the Above MP 58 SE
83. ired to activate a warning light a warning sound or to shut down the system under specified conditions The ML Trim comes factory pre loaded with default Control Parameters for Alarms These default parameter values are set for widely generic conditions that generally will not activate the alarm This allows you to either operate your system unfettered by the alarm or design your own alarm conditions that are unique to your system The factory default Control Parameters for the Alarms are found in Table 3 23 To modify these default parameters refer to Table 3 24 If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Table 3 23 Default Alarms Control Parameters CP Parameter Name Parameter Value CP 13 High Alarm 2000 CP 14 Ramped Error Alarm 2000 CP 15 Scaled Error Alarm 2000 Table 3 24 Entering Alarms Control Parameters CP Parameter Name Parameter Value Alarm Format This Control Parameter determines the circumstances under which the ML Trim will alert you to potential operating problems The alarm can be wired to activate a warning light a warning sound or to shut down the system under specified conditions Alarm Format CP 10 determines which alarm conditions will activate the Alarm output using the values that are entered in Low Alarm CP 12 High Alarm CP 13 Ramped Error Alarm CP 14 and Scaled Error Alarm CP 15 CP 12 Low Alarm Enter the RPMs at or be
84. lect page 2 12 J5 pins 3 5 Lead Frequency page 2 8 J5 pins 4 5 Feedback Frequency page 2 9 J5 pins 6 8 Run page 2 9 J5 pins 7 8 Jog page 2 10 J5 pins 9 11 R Stop page 2 10 Jog page 3 31 3 36 Glossary 6 Jog Input J5 pins 7 8 page 2 10 Jog Setpoint page 3 31 C 1 D 1 K Keypad Basic Entry page 3 4 Error page 3 45 C 7 E 1 Lockout page 3 5 C 14 D 1 Index 6 Record of your Password page 3 6 Operation page 3 3 Test page 4 6 Glossary 6 Keys Code Select page 3 3 Glossary 3 Dedicated page 3 3 Numeric page 3 3 Glossary 7 Setpoint page 3 3 Tach page 3 3 Up Down Scroll page 3 3 Glossary 10 L Lead Frequency page 3 40 C 4 E 1 Input J5 pin 3 5 page 2 8 LED Display page 3 3 Glossary 6 LOC page 3 5 Logic Inputs page 3 34 Glossary 6 Inputs Group A page 3 41 C 8 E 1 Inputs Group B page 3 41 C 9 E 1 Output page 3 37 Outputs page 3 42 C 9 E 1 Logic Control page 3 33 Low Alarm page C 2 D 1 M Host page 3 49 Master Follower Input J5 pins 12 14 page 2 11 Master Engineering Units page 3 9 C 3 D 1 Master Mode page 3 9 Glossary 7 Application page 1 4 Example page 3 12 Master Setpoint 1 page C 1 D 1 Master Setpoint 2 page C 1 D 1 Max RPM Feedback page 3 9 3 13 C 4 D 1 Max RPM Lead page 3 13 C 4 D 1 ML Trim Example of Application page 1 4 Internal Structure page 3 43 Introducing the page 1 3 Mounting See M
85. llower sensor shaft feedback and Lead sensor shaft feedback to calculate any speed error When the ML Trim finds speed error the control algorithm adjusts the Speed Command Out to the motor drive and reduces the error to zero Lead Motor Drive ML Trim Feedback Frequency A Ingredient A Sensor 9 gt gt Q 0 Final Product Pump N Lead Motor Follower Motor Drive ML Trim Feedback Frequency Follower Motor gt Sensor 9 Q me gt Pump Q Ingredient B Figure 1 2 ML Trim Follower Mode NOTES Installation Setup Mounting Wiring Inputs Outputs Serial Communications Calibration Motor Drive Setup ML Trim Calibration CUTOUT ee 5 us From the rear of the door panel to the back of the connectors Figure 2 1 ML Trim Cutout Dimensions and Mounting Guide MOUNTING This section contains instructions for mounting the ML Trim in the door panel of a NEMA Industrial Electrical enclosure The ML Trim is packaged in a compact 1 4 DIN Vertical Instrument Enclosure that mounts easily in the door of your Industrial Electrical Enclosure The Electrical Enclosure must have an IP54 rating or higher to comply with CE installations To mount the ML Trim 1 The NEMA Industrial Electrical Enclosure that will house the ML Trim must conform to the following environmental conditions Temperature 0 55 degrees C Internal NEMA enclosure temperature
86. low which you want the Alarm output to activate CP 13 High Alarm Enter the RPMs at or above which you want the Alarm output to activate CP 14 Ramped Error Alarm Enter the RPM Deviation between the Ramped Reference and the feedback that will activate the Alarm output Scaled Error Alarm Enter the RPM Deviation between the Scaled Reference and the feedback that will activate the Alarm output Jog Jog increases the RPMs at the acceleration rate that you specified in Acceleration Time CP 16 until the Jog Setpoint CP 05 is achieved When Jog is terminated there is no Deceleration Time CP 17 the drive comes to an immediate stop The factory default Control Parameter for Jog is found in Table 3 25 To modify this default parameter refer to Table 3 26 If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Table 3 25 Default Jog Control Parameters CP Parameter Name Parameter Value Table 3 26 Entering Jog Control Parameters CP Parameter Name Parameter Value CP 05 Jog Setpoint Enter the RPM at which you want your system to operate when it is in Jog For information on the Jog Logic Input refer to Logic Control Logic Inputs Jog page 3 36 31 32 NOTES LOGIC CONTROL This section addresses the four digital inputs and one digital output that control the ML Trim s operating state The four digital inputs F Stop R Stop Run Jo
87. mation Max RPM Feedback CP 34 Measured at the sensor shaft this number is the maximum RPMs at which you want your system to operate This number is identical to the maximum operating speed that you set in step 7 of the calibration procedure on page 2 20 PPR Feedback CP 31 The number of gear teeth or number of encoder lines on the feedback sensor per one revolution pulses per revolution Master Engineering Units CP 20 The actual value of the Master Engineering Units if the system were to operate at the maximum RPMs that you entered in Max RPM Feedback CP 34 The factory default Control Parameters for Scaling are found in Table 3 4 To modify the default parameters refer to Table 3 5 If you are uncertain how to enter a Control Parameter review the Operations Keypad section page 3 3 Information on setpoint entry follows Table 3 5 10 Table 3 4 Default Master Scaling Control Parameters Parameter Name Parameter Value CP 34 Max RPM Feedback 2000 CP 20 Master Engineering Units 2000 Table 3 5 Entering Master Scaling Control Parameters CP Parameter Name Parameter Value Max RPM Feedback Enter the maximum desired RPMs measured at the sensor shaft CP 31 PPR Feedback Enter the number of gear teeth or encoder lines on the sensor per one revolution pulses per revolution Master Engineering Units Enter the Master Engineering Units value if the system were to operate at the maximum desired RPMs entere
88. ment or connections can cause injury or death Line Neut F Stop Start l_ Armature M1 AUX1 Contactor 5V COM_AUX DI 5V Ext COM Pwr Supply LEAD_FQ he FDBK_FQ Feedback MAX_SPD COM Freq RUN Run Speed DRV_SIG JOG zum DRV_COM COM SNI HTIS OL STVNINYAL P N3 LHOI L NINO 9 SZ 09 ALIOVdIAV OL R STOP R Stop F STOP F Stop AC POWER 115 VAC 0 1 AMPS 50 60 Hz 4 COM MST FOL SETPT COM V DO EN ALARM 3ZIS 34IM 193 13S A INO 3HIM H3ddOO ASN COM Figure G 4 Start Stop for Non Regen with Armature Contactor DANGER This diagram is for conceptual purposes only Use safety equipment Make wiring connections carefully Incorrect use of equipment or connections can cause injury or death ER INWOO S8vSH SNI 81S OL S IVNIIWH3L f N31H9IL NINO 3UIM 9 92 09 HOS ALIOVdIAV OL INC 3716 SYIM 193138 1 3HIM H3ddOO ASN MAX SPD Speed SIG Gi Command SIS Out DRV COM J2 AC POWER 115 VAC 0 1 AMPS 50 60 HZ L1 9 NEUT 23 e m GND 3 PE J1 255 a5 88 300 mazo Za 29 5 2 OM AUX oom 2 DOS E Oy 5 55 T ar aa SI ni E 9 9 m Gut DRV_COM EAS p 3m J2 284 eas D AC POWER 115 0 1 AMPS EE 50 60 HZ 2 lt
89. mp delivers 30 gallons minute when the motor is running at a maximum RPM of 1800 The Follower sensor shaft is equipped with a 30 tooth Ring kit Follower Setpoint 1 will be set so that when the Lead pump delivers 5 gallons minute the Follower pump will deliver 15 gallons minute Follower Setpoint 2 will be set so that when the Lead pump delivers 5 gallons minute the Follower pump will deliver 22 5 gallons minute Table 3 11 shows the Control Parameters that would be entered in the ML Trim for Example A To find the ratio for the Follower Engineering Units CP 21 for Example A Follower E U at Max Follower RPM 30 Follower E U CP 21 z 3 Lead E U at Max Lead RPM 10 30 gal min The Follower Engineering Units when the Follower is operating at the maximum RPM Divided by 10 gal min The Lead Engineering Units when the Lead is operating at maximum RPM Equals O e Follower Engineering Units CP 21 as a ratio of Follower to Lead To find Follower Setpoint 1 CP 03 for Example A Follower E U desired 15 Setpoint 1 3 Lead E U operation 5 15 gal min The Follower Engineering Units gallon per minute at which you want the Follower to operate do not confuse this with the full capacity gal min that the Follower is capable of pumping Divided by 5 gal min The Lead Engineering Units that the Lead is operating at do not confuse this with the full capacity that the Lead is capable of operating
90. nd calibrate your ML Trim determine which of the modes of operation your ML Trim is set up for The mode of operation that you use is determined by your systems operational requirements The following subsections demonstrate how to enter Control Parameters for the Direct mode Master stand alone mode or the Follower mode of operation In addition Control Parameters for speed change stability warning methods and fast forward are addressed in the subsections on Acceleration Deceleration Tuning Alarms and Jog Direct Mode In the Direct mode of operation the Speed Command output from the ML Trim that is connected to the motor drive can be set directly Direct mode is an open loop mode of operation Scaling Acceleration Deceleration and closed loop compensation PID software are not involved in the Direct mode The Direct mode is used in conjunction with the Run and Stop controls Caution To avoid damage to your system the ML Trim must be calibrated and the motor drive set up before you enter the Direct Control Parameters Refer to Installation Setup Calibration page 2 17 The Direct Setpoint CP 06 is entered as a percentage of the ML Trim s calibrated full scale Speed Command output To enable or disable Direct mode use the Direct Enable CP 61 The factory default Control Parameters for the Direct mode are found in Table 3 2 To modify the default parameters refer to Table 3 3 If you are uncertain how to enter a Cont
91. ommon In the example below Setpoint Select is the open or logic high level Code Master or Follower 5 12 Setpoint Select 5 Pin 1 Not Used Not Used MP 56 LOGIC OUTPUTS The Logic Outputs MP 56 displays the status of the Drive Enable and Alarm logic outputs The number 1 indicates an inactive or de energized logic high level The number 0 indicates an active or energized logic low level In the example below Alarm is the inactive or de energized logic high level Code Drive Enable J5 Pin 16 Alarm J5 Pin 17 Not Used Not Used MP 57 EEPROM STATUS The Control Parameters are stored in the EEPROM memory chip EEPROM Status MP 57 displays the status of the EEPROM memory chip The number 0 indicates no failure The number 1 indicates a write verify error In the event of an error call Technical Support at 612 424 7800 or 1 800 342 4411 MP 58 SERIAL COMMUNICATIONS ERROR Serial Communications Error MP 58 identifies errors in the last transmitted message that was sent to the ML Trim by the host computer The mode that displays a number 1 indicates the error In the example below Invalid Parameter Code is the error Code Structure Error Parity Framing No ETX No STX Invalid Parameter Code Invalid Parameter Data or Out of Data Min Max Range Control Mask Error MP 59 FREQUENCY OVER FLOW COUNTER The Frequency Over Flow Counter MP 59 is a counter t
92. ons per minute Master Setpoint 1 will be setup to pump 10 gallons per minute when it is the active setpoint Master Setpoint 2 will be setup to pump 5 gallons per minute when it is the active setpoint Table 3 7 shows the scaling Control Parameters that would be entered in the ML Trim for this example Table 3 7 Master Mode Control Parameters Example CP Parameter Name Parameter Value CP 34 Max RPM Feedback 1725 CP 20 Master Engineering Units CP 02 Master Setpoint 2 5 After the Scaling and the Master Setpoints for your system have been entered you can enter the Acceleration Deceleration Control Parameters for the Master mode The Acceleration Deceleration Control Parameters are identical for both the Master and the Follower modes of operations Acceleration Deceleration is discussed in Operation Control Parameters Acceleration Deceleration page 3 26 The following section demonstrates how to enter Control Parameters for the Follower mode of operation Follower Mode The Follower mode of operation is the most frequently used mode of operation Itisa multi motor operation in which the entire process can be controlled by any number of motors and ML Trims Caution To avoid damage to your system the ML Trim must be calibrated and the motor drive set up before you enter the Follower Control Parameters Refer to Installation Setup Calibration page 2 17 The ML Trim allows you to control your system in Follower Engineerin
93. ou can enter values for Follower Setpoints 1 and 2 CP 03 CP 04 The value that you enter for a setpoint is the ratio of the Follower E U s at which you want to operate the system divided by the E U s that the Lead is operating at Follower E U desired Setpoint Lead E U operation You can toggle between the two setpoints if you have wired the Setpoint Select accordingly Setpoint Select located at J5 pins 13 14 determines which of the two setpoints is active refer to Setpoint Select on page 2 12 The factory preset default Follower Setpoints 1 and 2 CP 03 and 04 are set at 0 To modify these default parameters refer to Table 3 10 Table 3 10 Entering Follower Setpoint Control Parameters CP Parameter Name Parameter Value Follower Setpoint 1 Divide the Follower E U that you want by the Lead E U that the Lead is operating at and enter that value Follower Setpoint 2 Divide the Follower E U that you want by the Lead E U that the Lead is operating at and enter that value Examples of the Follower mode of operation are demonstrated on the following pages Follower Mode Examples A and B Example A demonstrates how scaling and setpoint Control Parameters are entered for a typical Follower mode of operation that uses a ratio setpoint The Lead pump delivers 10 gallons minute when the motor is running at maximum RPM of 1725 The Lead sensor shaft is equipped with a 60 tooth Ring kit The Follower pu
94. ounting the ML Trim Operation See Operation Mode of Operation page Glossary 7 Monitor Parameter Reference List page E 1 Monitor Parameters page 3 7 3 39 Glossary 7 Index 7 MP 00 page C 14 E 1 MP 40 page 3 43 C 4 E 1 MP 41 page 3 40 C 4 E 1 MP 43 page 3 40 C 5 E 1 MP 44 page 3 43 C 5 E 1 MP 45 page 3 44 C 5 E 1 MP 46 page 3 44 C 5 E 1 MP 47 page 3 42 C 6 E 1 MP 48 page 3 44 C 6 E 1 MP 50 page 3 45 C 6 E 1 MP 51 page 3 45 C 7 E 1 MP 52 page 3 46 C 7 E 1 MP 53 page 3 46 C 8 E 1 MP 54 page 3 41 C 8 E 1 MP 55 page 3 41 C 9 E 1 MP 56 page 3 42 C 9 E 1 MP 57 page 3 47 C 9 E 1 MP 58 page 3 51 C 10 E 1 MP 59 page 3 47 C 10 E 1 MP 99 page C 14 E 1 Monitor the Performance of the ML Trim page 3 43 Motor Does Not Run page 4 13 Does Not Stop page 4 12 Runs at Wrong Speed page 4 14 Runs Unstable page 4 15 Motor Drive Set Up page 2 18 Mounting the ML Trim page 2 3 Multidrop Installation Serial Communications page 2 15 O Open Loop page 1 3 Glossary 7 Operating State page Glossary 7 Operating States F Stop page 3 34 Jog page 3 36 R Stop page 3 34 Run page 3 35 Operation Acceleration Deceleration page 3 26 Alarms page 3 29 Control Parameters page 3 7 Direct Mode page 3 8 Follower Mode page 3 13 Example page 3 16 Index 8 Input Monitoring page 3 40 Inverse Follower Mode page 3 24 Example page 3 25 Inverse Master Mode page 3 22 Exam
95. page 3 9 3 13 C 4 D 1 CP 33 page 3 13 C 4 D 1 CP 34 page 3 9 3 13 C 4 D 1 CP 61 page 3 8 C 10 D 1 CP 62 page 3 22 3 24 C 11 CP 64 page 3 43 C 11 D 1 CP 65 page 3 27 C 11 D 1 CP 66 page 3 27 C 11 D 1 CP 67 page 3 27 C 12 D 1 CP 70 page 3 50 C 12 D 1 CP 71 page 3 50 C 12 D 1 CP 72 page 3 51 C 12 D 1 CP 73 page 3 51 C 13 D 1 CP 74 page 3 37 C 13 D 1 CP 98 page 3 5 C 14 D 1 Control State page 3 46 C 8 E 1 D Data Inquiry page Glossary 4 Serial Communications page 3 62 Deceleration Time page C 3 D 1 Dedicated Keys page Glossary 4 See also Keys Dedicated Derivative page 3 27 C 12 D 1 Deviation page 3 43 C 2 C 5 E 1 Device Address page 3 50 C 12 D 1 Diagnostics page 4 3 Automatic Test Routines page 4 10 Digital Motor Controller page Glossary 4 Index 4 Direct Enable page 3 8 C 10 D 1 Direct Mode page 3 8 Glossary 4 Direct Setpoint page 3 8 C 2 D 1 Display Mode Follower page 3 43 C 11 D 1 Display Test page 4 5 Glossary 4 Drive Enable page 3 37 Glossary 5 Logic page C 13 D 1 Output J5 pin 16 page 2 13 E EEPROM page Glossary 5 EEPROM Status page 3 47 C 9 E 1 Enclosure Mounting and Housing the ML Trim page 2 3 Engineering Units page Glossary 5 F F Stop page 3 34 Glossary 5 Input J5 pins 10 11 page 2 11 Fax Cover Sheet page F 1 Feedback Frequency page 3 40 C 5 E 1 Input J5 pins 4 5 page 2 9 Follower Engineerin
96. paired or replaced without charge providing it is shipped prepaid to Contrex Inc 8900 Zachary Lane North Maple Grove Minnesota 55369 Spare Parts Contrex Inc will usually have an adequate inventory of spare parts and circuit boards for all standard products However purchasers are encouraged to maintain a nominal supply of spare parts to insure immediate on site accessibility Instruction Manuals Instructions for installation maintenance and troubleshooting are included in manuals that are provided with the equipment Repairs may be performed in the field by competent customer personnel but in order to not invalidate the warranty they must be made in strict accordance with published instructions and ONLY AFTER obtaining approval of the Technical Service Department such repairs are usually limited to the replacement of circuit boards and major subassemblies not the repair of these items OEM Service In many instances Contrex Inc products are sold to the original equipment manufactures or integrators for inclusion in larger systems In such cases the obligations of Contrex Inc extend only to that original purchaser It is the latter s responsibility to handle any service required by his customer the end user Such problems can usually be solved by field replacement of complete units OEM s are encouraged to buy and maintain a supply of loaners for this purpose Contrex Inc will provide factory overh
97. parts and components In either instance the device that is returned to the purchaser meets full factory standards for new device performance If there is less than 90 days remaining on the warranty period at the time of the repair the warranty will extend to 90 days after the repair Parts and services outside the scope of this Warranty 4 warranty will be available at Contrex Inc current market price Contrex s liability for a device or it s use whether in warranty or not shall not in any instance exceed the cost of correcting the defects of the device Contrex Inc assumes no responsibility for damage to property or injuries to persons from improper use of this device No express warranties and no implied warranties whether of merchantability or otherwise except as to title other than those set forth above which are expressly made in lieu of all other warranties shall apply to any devise sold by Contrex Inc Contrex Inc reserves the right to change or improve its devices without imposing any obligation upon Contrex Inc to make changes or improvements in previously manufactured devices This warranty statement is a summary of Contrex Inc s policy Further limits of liability are contained in the Contrex Inc s purchase order acknowledgments and invoices Index Index A AC Power Input J3 pins 1 2 3 page 2 8 Acceleration Time page C 3 D 1 Acceleration Deceleration page 3 26 Glossary 3
98. pen J5 pin 6 and J5 pin 9 Open J5 Pin 7 Consult Tech Beben Support A 1 800 342 4411 orrecte Figure 4 1 Motor Does Not Stop Flowchart MP 53 MP 53 1000 F Stop kpo R Stop Yes J5 Pin 10 is J5 Pin 9 is shorted shorted to common to common Yes Short J5 Pin 10 to common Short J5 Pin 9 io common Problem Corrected Consult Tech Support Figure Motor Does Not Run Enter Correct Yes Jog Setpoint Yes 4 2 No MP 53 MP 53 ooto Rur No Yes Yes CP 05 is correct MP 50 MP 50 0010 Master 0100 Follower Setpoint is correct Yes MP 45is Correct MP 46 is Correct Yes MP 47 is Zero Check Drive Wiring Enter Correct Scaling Problem Corrected No Enter Correct Setpoint No Motor Does Not Run Flowchart MP 50 0001 Direct CP 06 is correct Yes Consult Tech Support 1 800 342 4411 Motor Runs at Wrong Speed MP 50 MP 50 MP 50 0010 Master L 0100 Follower Lo 0001 Direct No No Setpoint is correct CP 06 is correct Enter Correct Setpoint MP 45 is correct Repeat Calibration Procedure MP 46 is Enter Correct correct Scaling MP 48 is Negative Problem Corrected Consult Tech Support 1 800 342 4411 Problem
99. ple page 3 23 Jog page 3 31 Keypad Operation page 3 3 Logic Control page 3 33 Logic Inputs page 3 34 Logic Output page 3 37 Master Mode page 3 9 Example page 3 12 Monitor Parameters page 3 39 Output Monitoring page 3 42 Performance Monitoring page 3 43 Serial Communications page 3 49 Communications Software Design page 3 52 Using Serial Communications page 3 50 Status Monitoring page 3 45 Tuning page 3 27 Output Monitoring page 3 42 Glossary 8 Test page Glossary 8 Test 5 page 4 8 Test 6 page 4 9 Wiring page 2 13 P Parameter page 3 7 Glossary 8 Code page 3 7 3 39 Glossary 8 Send page 3 53 Glossary 8 Summary Reference List page C 1 Value page 3 7 3 39 Glossary 8 Performance Monitoring page 3 43 Glossary 8 PPR Feedback page 3 9 3 13 C 4 D 1 Lead page 3 13 C 3 D 1 PROM Chip page Glossary 8 Chip Replacement page 4 16 Test page 4 10 Glossary 8 R R Stop page 3 34 Input J5 pins 9 11 page 2 10 Index 9 RAM Test page 4 4 4 10 Glossary 9 Ramped Error page C 2 D 1 Ramped Reference page 3 44 C 5 E 1 Remote Control of the ML Trim page 3 49 Revision Log page H 1 Ring Kits page Glossary 9 RPM Feedback page Glossary 9 RPM Lead page Glossary 9 RS485 page 3 49 Run page 3 35 Glossary 9 Input J5 pins 6 8 page 2 9 S Scaled Error page C 3 D 1 Scaled Reference page 3 44 C 5 E 1 Scaling page Glossary 9 Serial Communications page 3
100. r device Master or Follower J5 pins 12 14 This input determines the ML Trim s mode of operation and resulting scaling formula that the control algorithm uses The ML Trim is in Master mode when the circuit is open and Follower mode if the circuit is shorted to the common Figure 2 11 F Stop MASTER FOLLOWER Figure 2 12 Master Follower Setpoint Select J5 pins 13 14 The Master and Follower setpoints are determined by the Setpoint Select CONTROL input combined with the Master PARAMETER 1083 Follower Input For access to Master Control Parameters 1 and 2 and Follower Control Parameters 3 and 4 g CONTROL refer to the chart below PARAMETER 2 OR 4 Figure 2 13 Setpoint Select Setpoint Select Open Setpoint Select Closed Master Follower Input Open Master Control Parameter 1 Master Control Parameter 2 Master Follower Input Closed Follower Control Parameter 3 Follower Control Parameter 4 OUTPUTS NOTE The installation of this motor control must conform to area and local electrical codes See The National Electrical Code NEC Article 430 published by the National Fire Protection Association or The Canadian Electrical Code CEC Use local codes as applicable Speed Command Out J2 pins 1 2 Speed Command Out is an isolated analog output signal that is sent to the motor drive to control the speed of the motor Wire the Speed Command Out into the Speed Signal Input of the
101. rol Parameter review the Operations Keypad section page 3 3 Table 3 2 Default Direct Mode Control Parameters CP Parameter Name Parameter Value Direct Enable Table 3 3 Entering Direct Mode Control Parameters CP Parameter Name Parameter Value Direct Setpoint Enter the percentage of the calibrated full scale Speed Command output at which you want your system to operate Direct Enable Enter 1 to enable the Direct Mode Enter 0 to disable the Direct Mode Master Mode The Master or stand alone mode of operation is a single motor operation In this simple mode of operation the entire process is controlled by a single motor and one ML Trim Caution To avoid damage to your system the ML Trim must be calibrated and the motor drive set up before you enter the Master Control Parameters Refer to Installation Setup Calibration page 2 17 The ML Trim allows you to control your system in Master Engineering Units e g RPMs gallons per hour feet per minute The Master Engineering Units at which you want the system to operate are entered into the two available Master Setpoints CP 01 and CP 02 However before the ML Trim can determine how to operate at those setpoints you must enter Scaling Control Parameters into the ML Trim Scaling is a convenient method for translating the relationship of the motor RPMs into Master Engineering Units The Scaling Control Parameters give the ML Trim the following infor
102. tegories of Monitor Parameters Input Monitoring Output Monitoring Performance Monitoring Status Monitoring In the subsections that follow the Monitor Parameters are listed according to these categories 40 Input Monitoring These MPs monitor the ML Trim s inputs MP 41 LEAD FREQUENCY The Lead Frequency MP 41 displays the frequency of the Lead Frequency Input J5 pin 3 in units of hertz pulses per second The Lead Frequency MP 41 is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update Because the Lead Frequency MP 41 is not averaged or filtered and because of sensor irregularities it may appear less stable than Tach MP 40 Numbers that are larger than 9999 are displayed with two decimal places For example 10 000 hertz is displayed like the figure below in MP 43 MP 43 FEEDBACK FREQUENCY The Feedback Frequency MP 43 displays the frequency of the Feedback Frequency input J5 pin 4 in units of hertz pulses per second The Feedback Frequency MP 43 is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update Because the Feedback Frequency MP 43 is not averaged or filtered and because of sensor irregularities it may appear less stable than Tach MP 40 Numbers that are larger than 9999 are displayed with two decimal places For example 10 000 hertz is displayed as follows Two Decimal Places MP
103. ter 11 Data Format Character 11 indicates the decimal location and polarity of the data that was transmitted in characters 7 through 10 Use the following codes to indicate decimal location and polarity O O O Format XXXX XXX X XX XX X XXX XXXX XXX X XX XX X XXX NOOA Codes 0 through 7 are valid for 20 CP 21 All other Code Parameters have either fixed or derived decimal locations and must use Code 0 Code 8 does not apply to the parameter send Character 12 ETX Always use the ASCII ETX character to terminate the character string Example of Parameter Send A new Acceleration Time of 52 3 seconds is sent to the ML Trim at address 4 ASCII character string STX0431605230ETX Note The character string has no spaces between the integers 55 Table 3 30 Parameter Send ML Trim Response E ER HN RI E DEV DEV ERROR PAR PAR DATA DATA DATA DATA DATA DESC STX 10s 15 10s 15 10005 1005 10s 15 FORM fe e pa The following is a description of the Parameter Send ML Trim Response Characters Character 1 STX This is the first character in the character string Characters 2 3 Device This is the two character access address for the ML Trim Character 4 Error Code If there are errors in the transmission that the ML Trim receives from the
104. the inactive or de energized logic high level Code Drive Enable J5 Pin 16 Alarm J5 Pin 17 Not Used Not Used Performance Monitoring Performance Monitor Parameters monitor the performance of the ML Trim and your system Figure 3 2 is a block diagram of the internal control structure of the ML Trim and the Performance Monitor Parameters Active Feedforward Scaling MP 50 px Scaled Deviation Ref gt ee ME Speed Command requency Maste MP 41 r m Out MP 47 gt Follower p Reference MP 46 Feedback Frequency MP 43 Feedback Tach Scaling MP 40 Figure 3 2 ML Trim Internal Structure MP 40 TACH Tach MP 40 is the feedback displayed in scaled Engineering Units or RPM In the Master mode Tach MP 40 will display the feedback in Master Engineering Units CP 20 In the Follower mode Tach MP 40 will display either the E U s Time or the feedback to Lead ratio in Follower Engineering Units CP 21 depending on the value in Display Mode Follower CP 64 In Jog or the Direct mode Tach MP 40 will display the feedback in RPMs The feedback is read by the ML Trim every ten milliseconds The readings are summed then averaged for one second before the Tach is displayed MP 44 DEVIATION ERROR Deviation MP 44 displays the difference between the Ramped Reference MP 46 and the Feedback Frequency MP 43 measured in units of hertz pulses per second Devi
105. tion The primary disconnect device must meet EN requirements Inductive coils on relay contactors solenoids that are on the same AC power line or housed in the same enclosure should be suppressed with an RC net work across the coil For the best results use resistance r values of 50 ohms and capacitance c values of 0 1 microfarads Install an AC line filter or isolation transformer to reduce excessive EMI noise such as line notches or spikes on the AC power line DANGER Hazardous voltages Can cause severe injury death or damage to the equipment The ML Trim should only be installed by a qualified electrician NOTES INPUTS NOTE The installation of this motor control must conform to area and local electrical codes See The National Electrical Code NEC Article 430 published by the National Fire Protection Association or The Canadian Electrical Code CEC Use local codes as applicable Power J5 pins 1 2 5VDC MAXIMUM For isolated operations the Frequency Inputs J5 pins 3 4 5 the Digital Inputs J5 pins 6 14 and 5VDC the Digital Outputs J5 pins 15 18 External require an external source of Power 5VDC power y Supply CAUTION The ML Trim is shipped from the factory non isolated with J4 and J5 jumpers Do not connect the External Power Supply You must remove the J4 and J5 Common to Earth Ground jumpers before you connect the External Power supply or you can Figure 2
106. trol Parameters Example 3 23 Default Inverse Follower Control Parameters 3 24 Entering Inverse Follower Control Parameters 3 24 Inverse Follower Mode Control Parameters Example 3 25 Default Master or Follower Accel Decel Control Parameters 3 26 Entering Master or Follower Accel Decel Control Parameters 3 26 Default Master or Follower Tuning Control Parameters 3 27 Entering Master or Follower Tuning Control Parameters 3 28 Default Alarm Control Parameters 3 29 Entering Alarm Control Parameters 3 30 Default Jog Control Parameters 3 31 Entering Jog Control Parameters 3 31 Default Drive Enable Logic Control Parameters 3 37 Entering Drive Enable Logic Control Parameters 3 37 Parameter Send Host 3 53 Parameter Send ML Trim Response 3 56 Control Command Send Host Transmission 3 58 Control Command Send ML Trim Response 3 60 Data Inquiry Host Transmission 3 62 Data Inquiry ML Trim Response 3 64 ASGIItO BIDary rn ee en Ted ias
107. try status or performance monitoring and remote control of the ML Trim See Operations Serial Communications page 3 49 for information on using Serial Communications The ML Trim is designed to use with an isolated RS232 to RS485 converter Figure 2 16 illustrates a multidrop installation of the Serial Communications link and Figure 2 17 illustrates the Serial Communications connections Isolated RS232 to RS485 Converter Figure 2 16 ML Trim Multidrop Installation Isolated RS232 to RS485 Converter TXD TXD COM RXD RXD ML Trim 1 ML Trim 2 1 Shield only at one end of the cable 2 If you need to terminate the communication line then terminate it at the unit which is the furthest away from the converter A 100 ohm 1 2 Watt resistor will usually terminate successfully Refer to EIA Standard RS485A for more information Figure 2 17 ML Trim Serial Communications Connections CALIBRATION Calibration matches the Speed Command analog output of the ML Trim with the analog input of the motor drive Calibration is accomplished in two steps The first step is to set up the motor drive The second step is to calibrate the ML Trim to the motor drive so that the speed is adjusted to the maximum operating speed The ML Trim must be properly installed prior to calibration Refer to nstallation Setup Mounting page 2 3 and nstallation Setup Wiring page 2 5 AX DANGER Hazardous voltages Can cause se
108. tus of the keypad lockout When the keypad is locked then LOC is displayed When the Keypad is unlocked then ULOC is displayed To lock out the keypad enter a numerical password between 1 and 9999 in Keypad Lockout CP 98 This numerical password will flash briefly on the screen then the screen will display LOC To unlock the keypad enter the same numerical password in Keypad Lockout CP 98 The number will flash briefly on the screen and then the screen will display ULOC Control Parameters and Monitor Parameters may be monitored during lockout however Control Parameters can not be changed during lockout The Clear 7 procedure will default Keypad Lockout CP 98 unlocked CAUTION Make certain that you record your password as it becomes transparent once you have entered it If you forget your password you can use the Clear 7 procedure to revert back to the default ULOC unlocked Please note however that the Clear 7 procedure will revert all of the Control Parameters back to their original default values and you will lose any changes that you have made to the Control Parameters Therefore make certain that you have recorded all Control Parameter changes in the space provided in Appendix D before you use the Clear 7 procedure Refer to Troubleshooting Troubleshooting page 4 11 for instructions on the Clear 7 proce dure MP 99 SOFTWARE CODE REVISION Software Code Revision MP 99 displays the code
109. vere injury death or damage to the equipment Make adjustments with caution MOTOR DRIVE SET UP Put the ML Trim in R Stop by opening the R Stop input J5 pins 9 11 Refer to Installation Setup Wiring Inputs R Stop page 2 10 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 ML Trim to control the speed changes If the drive has a Maximum Speed Span Potentiometer set it to the highest setting at which the motor drive is capable of running The maximum speed at which you want the system to operate will be controlled by the ML Trim If the drive has a Zero Speed Potentiometer adjust it to eliminate any motor creep If the drive has an IR Compensation Potentiometer set it at minimum Each motor drive has settings that are unique to its particular model Adjust any remaining drive settings according to the manufacturer s recommendations ML TRIM CALIBRATION 1 Make sure that the ML Trim is still in R Stop If the ML Trim is not in R Stop then put it in R Stop by opening the R Stop Logic input J5 pins 9 11 Refer to nstallation Setup Wiring Inputs R Stop page 2 10 Enter the resolution PPRs of the feedback sensor in the PPR Feedback Control Parameter CP 31 by entering the following on the keypad Press Code Select Enter 31 PPR
110. ways be 0 Character 11 Data Format This character should always be 0 Character 12 ETX Always use the ASCII ETX character to terminate the character string 63 Table 3 34 Data Inquiry ML Trim Response EON AAA DEV DEV PAR PAR DATA DATA DATA DATA DATA DESC STX 10s 1s 10s 15 1000s 1005 10s 1s FORM The following is a description of the Data Inquiry ML Trim Response Characters Character 1 STX This is the first character in the character string Characters 2 3 Device This is the two character access address for the ML Trim Character 4 Error Code If there are errors in the transmission that the ML Trim receives from the host computer the Error Code will display them Use Table 3 35 page 3 66 to convert the ASCII code to binary The binary code can be decoded as follows Bit7 Always 0 Bit6 Always 1 Bit5 1 Data was out of minimum maximum range Bit4 1 Checksum or Decimal Point Error Invalid Parameter Code Bit3 1 Receive buffer filled before ETX received or Message Format Error Bit2 1 Parameter Data Bit1 1 Parity Error BitO 12 Always 0 Note The ML Trim will only accept data if there are no errors The ASCII error code Binary code 1000000 indicates that the Host Transmission contains no errors Characters 5 6 Par
111. will activate the Alarm output using the values that are entered in Low Alarm CP 12 High Alarm CP 13 Ramped Error CP 14 and Scaled Error CP 15 See Figure 2 15 Refer to Operations Logic Control Logic Output page 3 37 for details NOTE This is an open collector relay driver Use an external DC power supply to power the relays Free wheeling diodes are incorporated internally in the ML Trim and do not need to be added externally V DO EXTERNAL Drive Enable Alarm SUPPLY Connon 50V Max Figure 2 15 Drive Enable and Alarm Outputs Auxiliary DC Power J4 pin 1 2 The 5 volt output J4 pin 1 is a DC regulated output that can be used to power encoders or other auxiliary equipment that is used in conjunction with the ML Trim If this output is used it will nullify optical isolation WARNING Do not exceed the maximum current output of 150 mA for 5 VDC Exceeding the maximum current output can damage the ML Trim SERIAL COMMUNICATIONS NOTE The installation of this motor control must conform to area and local electrical codes See The National Electrical Code NEC Article 430 published by the National Fire Protection Association or The Canadian Electrical Code CEC Use local codes as applicable The Serial Communications interface on the ML Trim complies with EIA Standard RS 485 A for balanced line transmissions This interface allows the host computer to perform remote computer parameter en
112. you resolve four possible system operating problems The four scenarios that are addressed by the flowcharts are Motor Does Not Stop Motor Does Not Run Motor Runs at Wrong Speed Motor Runs Unstable If you need to verify the integrity of the ML Trim independently refer to the Troubleshooting Diagnostics section page 4 3 If these troubleshooting procedures do not solve your problem perform a Clear 7 as follows Make a record of your current Control Parameter values When you perform the Clear 7 procedure all Control Parameters return to their default values Turn off the power to the ML Trim Press the Clear key and the 7 key then continue to press these keys while you apply power to the ML Trim The Clear 7 procedure restores the factory default settings and automatically performs the Power Up diagnostic routines Reenter the values for your Code Parameters If the information in this section does not solve your problem consult Contrex Technical Support 763 424 7800 or 800 342 4411 Motor Does Not Stop MP 53 MP 53 7 53 7 MP 53 1000 F Stop 0100 R Stop 0010 Run 0001 Jog J5 Pin 7 is shorted to common Remove wire at J2 Pin 1 J5 Pin 6 is Measure voltage with shorted to respect to J2 Pin 2 common Voltage 0 Wiring to Drive Motor Drive Calibration is correct is correct Problem Corrected O
113. you to customize for your systems specific needs the ML Trim s Monitor Parameters MPs allow you to monitor your system s performance The ML Trim s multiple scaling formats allow you to enter the setpoints and monitor speed in the Engineering Units e g RPMs gallons per hour feet per minute that are unique to your system Among the ML Trim s advanced capabilities is the flexibility to preset up to four setpoint entries Integrating the ML Trim s applied intelligence with your system puts precise speeds and perfect synchronization at your fingertips quickly easily and cost effectively EXAMPLES OF ML TRIM APPLICATIONS Figure 1 1 is an example of a Master mode of operation for a pump application The scaling format allows the operator to enter a setpoint in Engineering Units of gallons per minute The ML Trim compares the sensor shaft feedback to the scaled setpoint and calculates any speed error When the ML Trim finds speed error the control algorithm adjusts the Speed Command Out to the motor drive and reduces the error to zero cuida 500 HT E 5000 SO gem ML Trim Motor Drive Motor Pus Sensor Q Pump N Feedback Frequency Figure 1 1 ML Trim Master Mode Figure 1 2 is an example of the Follower mode of operation in a pump application The scaling format allows the operator to enter the setpoint as a ratio of ingredient B to ingredient A The ML Trim compares the setpoint ratio to the Fo

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