Electro-sensors, Inc. Microlength 196

Transcript

ELECTRO-SENSORS, INC. MicroLength 196 Length Control Manual Version 2.0 180.000 READY RUN REMOTE SETPT 1 STOP LOCAL SETPT 2 7 8 9 RUN 4 5 6 JOG 1 2 3 STOP POINT ENTER VAR 2ND FUNC 0 SET For Technical Assistance Call Electro-Sensors, Inc.: 1-800-328-6170 In MN (952) 930-0100 Fax (952) 930-0130 www.electro-sensors.com Manual part number = 990-000150 Rev A (Version 2.0) (00.08.22) Note: The material in this manual is subject to change without notice. (Version 2.0) (00.08.22) MicroLength 196 TABLE OF CONTENTS Section I Description Introduction---------------------------------------------------------------------------------------------Description Summary of Operation Details of Operation II MicroLength 196 Layout-----------------------------------------------------------------------------Front-Panel Dimensions, Panel Cutout Dimensions, Side-View Dimensions (with Mounting Bracket), Front-Panel Display and Keypad III Wiring and I/O Function-----------------------------------------------------------------------------Hardware Connections and I/O Summary Back-Panel Terminal Strips (Wiring Connections) Proper Wiring Methods AC Power Connections and AC Input Power Selection Connections to Variable Speed Motor Drive Feedback Encoder and MicroLength Compatibility Feedback Encoder Terminals & Sensor Configuration Switches Basic External Switch Inputs (Run, Stop, E-Stop, Jog) Other External Switch Inputs (Manual Run at High Speed, Fwd/Rev, Batch Reset, Local/Remote, Keypad Lockout, End Cycle, Set Point select) Status and Alarm Outputs IV Set-up Procedure--------------------------------------------------------------------------------------Calibrating the Analog Output (using Diagnostic Nine) Programming the System Set-up Variables Programming the Reference Length Variables Auto-Programming (Diagnostic Eight) Programming the Display Variables Programming the Status and Alarm Output Variables Programming the Batch Set-up Variable Programming the Length Set Points Programming the Fine-Tuning Variables Enabling Keypad Lockout V Programming Specifics------------------------------------------------------------------------------Entering Length Set Points Entering Variables List of MicroLength 196 Variables Variable Accessibility Reference Length Variables (Vars 01, 02, 03) System Set-up Variables (Vars 04, 05, 07-11, 18 & 29) Batch Set-up and Batch Monitor Variables (Vars 06, 23, 24) Display Variables (Vars 16, 17) Custom User Unit Label (Diagnostic Zero) System Performance Monitor Variables (Vars 25-28, 30-35) Status and Alarm Output Variables (Vars 21, 22, 38, 39) Fine-Tuning Variables (Vars 12-15) VI Diagnostics (2nd Function Key) -------------------------------------------------------------------VII Serial Communications (Via RS422)--------------------------------------------------------------Serial Communication Set-up Variables (Vars 19, 20, 47) Serial Communication Troubleshoot Variable (Var 48) Serial Communication Control and Monitor Variables (Vars 49-51, 53-57, 62, 63) Appendix A: MicroLength Program Record (Default values and user values)-------------------------Power-up with Software Reset Appendix B: Specifications------------------------------------------------------------------------------------Appendix C: Hookup Drawing--------------------------------------------------------------------------------Appendix D: Normal and Abnormal Run-Cycles, Other run-cycle events ----------------------------- Page - 1 Page 2 5 6 16 21 30 32 41 43 44 45 (Version 2.0) (00.08.22) TECHNICAL MANUAL For the MicroLength (uL196) Version 2.0 SECTION I INTRODUCTION Description: The MicroLength is a unidirectional length/batch controller for use in cut-to-length and material feed applications. The MicroLength is well suited for applications where system inertia is fairly constant from run-cycle to run-cycle. The MicroLength has four programmable length Set Points and one programmable batch Set Point. Note: The MicroLength runs in ‘open-loop’ speed control, meaning that no ‘on-the-fly’ corrections are made to ensure the feedback encoder RPM actually reaches the maximum RPM during the run-cycle. The MicroLength also runs in ‘open-loop’ length control, because any run-cycle ‘length’ errors are corrected for only during the next run-cycle. Summary of Operation: The MicroLength develops a run-cycle profile as shown in this drawing: Var31 Decel Correction Var05 MAX RPM Var09 High Speed % Var30 Stop Correction Var13 Creep Time Var10 Creep Speed % Var07 Accel Time Var08 Decel Time Analog Output cut-off point Set Point Length This profile enables the MicroLength to accurately and consistently move the desired length with the least possible opportunity for error: - Before beginning the run-cycle, the MicroLength calculates whether the Set Point length is long enough to reach Var09 High Speed for at least 200 msec. If the Set Point is too short to reach Var09 High Speed, then the MicroLength refuses to run the cycle, and displays the message “HiSpdErr” (high speed error). - The MicroLength accelerates the feedback encoder up to Var09 High Speed. - The MicroLength then runs at Var09 High Speed for the majority of the run-cycle (to minimize cycle time). - The MicroLength then decelerates the feedback encoder down to a Creep Speed, and runs there for a certain Creep Time to let the feedback encoder speed to stabilize. (Allowing the system to stabilize at a slower speed before the Set Point length is reached, permits the MicroLength to have very tight control, resulting in very good accuracy and Set Point repeatability for an ‘open-loop’ controlled system). Creep Speed and Creep Time can be adjusted to tailor the cycle profile to any system, to ensure accurate Set Points and minimum wasted move time. - Once the MicroLength has regained complete motor/encoder control in the Creep Speed portion, and the proper exact point has been reached just short of the Set Point length, the MicroLength cuts-off its Analog Output and the encoder ‘coasts’ to a stop landing right on the Set Point length. - This exact MicroLength profile does not happen on the first run-cycle, but only after the MicroLength’s correction-algorithm has ‘learned’ the system’s inertial behavior. - The MicroLength can abort the run-cycle for abnormal events. (See Appendix D for details on run-cycle aborts). Note: In this manual ‘length’ refers to motor/encoder travel and may relate to distance, length, volume, etc. Page - 2 (Version 2.0) (00.08.22) INTRODUCTION (cont.): Details of Operation: LEARNING System Inertial Behavior: During the first few run-cycles after set-up (or after certain critical variables are changed), the MicroLength effectively ‘learns’ the system’s hi-speed, deceleration and stopping behaviors; and adjusts itself accordingly. Details on how the MicroLength ‘learns’ a system’s inertial behavior are described here: 1) The MicroLength’s system behavior ‘learning’ process consists of resetting correction-factor Vars 30 and 31 to default values, and then letting the correction-algorithm ‘learn’ the new values needed for the system. The MicroLength must ‘learn’/’re-learn’ a system’s behavior if any of the following actions occur: - User changes (via keypad/serial) any of the specific ref/set-up/tuning Vars 01, 02, 03, 04, 05, 07, 08, 09, 10, 13. - User performs the ‘Diagnostic Eight auto-programming’ function. - User performs a ‘Power-up with software reset’. - User performs the ‘Diagnostic Seven software reset’ function. - User performs ‘Factory Default software reset’ via serial communications. 2) The MicroLength must run a few cycles on a good Set Point length (Var09 hi-speed reached for at least 200 ms) to ‘learn’ the system’s behavior, by trial and error. (During these first few run-cycles, the Set Point length may or may not be accurately reached, but not to worry, because the MicroLength is in the ‘learning’ process). 3) The actual ‘learning’ process begins with the Run command of each run-cycle, and ends when the Var12 SettleTime expires for each run-cycle. 4) The MicroLength is done ‘learning’ when its correction-algorithm can stop a run-cycle within ± Var21 Deviation pulses of the Set Point length. (After the ‘learning’ process is finished, the MicroLength still makes minor corrections from run-cycle to run-cycle, if necessary). 5) ‘Learned’ behavior is saved in correction-factor Vars 30 and 31 and is remembered even if the MicroLength is powered-down. 6) Once the MicroLength has ‘learned’ the system’s behavior, and nothing else changes except for the length Set Point, then if Var09 hi-speed is still reachable for at least 200 ms, the MicroLength does not need to ‘re-learn’. 7) However, the MicroLength must ‘re-learn’ if any of the actions listed in (1) above occur. Note: MicroLength version 2.0 indicates when it is in the ‘learning’ process. While ‘learning’, the MicroLength’s lower display message alternates between “LEARNING” and the ‘users Var17 display option’. - While learning, the MicroLength temporarily forgoes the “LEARNING” message (but not the learning process) if the VAR key is pressed, or if a STOP command (cycle-interrupt) is given. - While learning, the MicroLength cancels the “LEARNING” message (and the learning process) if the run-cycle aborts due to any one of the six run-cycle abort events. (The learning process resumes on the next run-cycle). (See Appendix D for details on the six abnormal run-cycle abort events). - If the MicroLength is powered-down before it is done ‘learning’ the system’s behavior, then the first time a Run command is given after it is powered-up again, it continues learning where it left off before the power-down, but it does not display “LEARNING”). ‘Open-loop’ Control Issues: Since the MicroLength is an ‘open-loop’ speed controller, there exists the possibility that the system’s feedback encoder may not ‘track’ exactly (in time and speed) to the MicroLength’s Analog Output. ‘Open-loop’ control is a simple control method, but its downfall is that it can result in poor run-cycle accuracy and repeatability if the system is not properly set-up: - Poor speed tracking (not obtaining expected speed) is a direct result of a poorly calibrated Analog Output. - Poor time tracking (motor/encoder sluggishness) is due to system inertia. Because of system inertia, the feedback encoder usually lags (in time response) behind the MicroLength’s Analog Output. 1) Poor speed tracking: The first and most important thing the MicroLength user can do to overcome this inherit downfall of the ‘open- loop’ control method, and thus improve run-cycle accuracy and repeatability, is to PROPERLY CALIBRATE the Analog Output!!! A properly calibrated Analog Output ensures that the feedback encoder runs at the desired maximum speed when the Analog Output is at its maximum of 99%. Page - 3 (Version 2.0) (00.08.22) INTRODUCTION \Details of Operation (cont.): ‘Open-loop’ Control Issues (cont.): 2) Poor time tracking: The other inherit downfall of ‘open-loop’ control is the time-lag due to inertia: - During acceleration at the start of a run-cycle, this time-lag may be evident if the Set Point lengths are quite short. What may happen, is the MicroLength’s Analog Output reaches its maximum voltage, and may already be in the deceleration ramp heading towards zero volts, before the time-lagging feedback encoder ever reaches maximum speed. To help compensate for this, the MicroLength requires the actual Set Point length be equal or greater than a theoretical Minimum Set Point length (for a perfectly calibrated system). If the actual Set Point is less than the MinSetPt value, then the MicroLength does not begin the run-cycle. - During deceleration from Maximum Speed to a stop, this time-lag can also be evident. If this time-lag is long enough, then the MicroLength’s Analog Output may stop (reach 0 volts) before the feedback encoder stops: in a sense the MicroLength loses control of the system. To help compensate for this time-lag tracking error, the MicroLength decelerates the system from Maximum Speed slightly sooner than it normally would, bringing the Analog Output down to a Creep Speed, then running at Creep Speed for a set amount of Creep Time. This ‘buys a little time’ after the decel ramp, which gives the feedback encoder’s speed a chance to stabilize, catch-up and track the MicroLength's Analog Output. This allows the MicroLength to regain complete motor/encoder control before reaching the Set Point length. Feedback Encoder ‘Reverse-Detection’ at End of Run-Cycle: MicroLength version 2.0 can detect if the feedback encoder is pulled backward at the end of a run-cycle (usually by the elasticity of the material on the process line) and can compensate for it by including the ‘pullback’ into the system behavior ‘learning’ process. However, this requires the use of a quadrature encoder and our external ‘Quad Encoder Input Adapter’. The ‘Quad Encoder Input Adapter’ takes the two quadrature signals from the quadrature encoder as its inputs, and produces two outputs, one a COUNT-UP signal (for forward direction), the other a COUNT-DOWN signal (for reverse direction). When operating with ‘reverse-detection’ (using a quad encoder and the external Quad Encoder Input Adapter), use as follows: - The COUNT-UP signal is sent to the MicroLength’s TB1-2 input (encoder Feedback ‘A’ Frequency input). - The COUNT-DOWN signal is sent to the MicroLength’s TB1-3 input (encoder Feedback ‘B’ Frequency input, an unused input in MicroLength version 1.0). - For ‘reverse-detection’, Var17 Display Selection 0 (length in ‘User Units’) only displays non-negative numbers. (If you try to run the encoder in reverse all the way back to ‘zero length’ and further, the MicroLength ignores any more COUNT-DOWN pulses and holds the upper display at 0). Notes: - This ‘reverse-detection’ feature is not intended for using the MicroLength as a bi-directional position controller. - If reverse direction is tried (without first swapping the COUNT-UP/COUNT-DOWN inputs), the MicroLength just creeps the encoder/motor in reverse. - If Var17 Display Selection is 1 or 2, and if reverse direction is tried (without first swapping the COUNT-UP/COUNT-DOWN inputs), then the upper display shows 99999.9 only. For standard operation without reverse-detection, use as follows: - Connect the single channel encoder’s output signal directly to the MicroLength’s TB1-2 input (encoder Feedback ‘A’ Frequency input). Page - 4 (Version 2.0) (00.08.22) SECTION II MicroLength 196 LAYOUT Shown below are the MicroLength’s: - Front-Panel dimensions - Panel Cut-out dimensions (for inserting the MicroLength into a control cabinet door, etc.,) - Side-view dimensions (shown with Mounting Bracket) - Front-Panel Display and Keypad 5.66" Front Panel 2.94" 5.433" 2.677" Panel Cutout MicroLength 196 Enclosure Mounting Bracket 2.6" 6.5" 7.2" MicroLength 196 Front-Panel 180.000 READY RUN REMOTE SETPT 1 STOP LOCAL SETPT 2 Page - 5 7 8 9 RUN 4 5 6 JOG 1 2 3 STOP POINT ENTER VAR 2ND FUNC 0 SET (Version 2.0) (00.08.22) SECTION III WIRING AND I/O FUNCTION Hardware Connections and I/O Summary: At a minimum, the MicroLength requires connections for: - AC power. - Analog Output to the variable speed motor drive. - Feedback encoder input. - (STOP & E-STOP external control inputs must have jumpers if not used). External control inputs for Run, Stop, Jog, and E-Stop are provided, but their use is not required. Other external control inputs (whose use is not required) include: Analog Output Polarity (Fwd/Rev) selection, manual Run at High Speed, End Cycle (abort) while at interrupt-stop, Set Point selection, Batch Reset, Local/Remote mode, and Keypad Lockout. Six transistor alarm outputs are provided by the MicroLength for both control and status indication (their use is not required). The transistor outputs are: Drive Enable, At Position (cycle complete), Deviation from Set Point, Cut-Signal, Running at Low Speed, and Batch Complete. The Drive Enable output is designed to turn ON and OFF the controlled drive based on the state of operation. Usage of the Drive Enable output is not required, but highly recommended. 9 Keypad Lockout Emergency Stop 10 11 12 7 Run Stop (Interrupt Cycle) Common Local/Remote Common 8 6 Jog Common N/A Stpt 3&4 Enable 5 4 Common Run at High Speed Common End Cycle Common 3 2 Batch Reset Stpt 1(3) / Stpt 2(4) Feedback (B) Frequency N/A 1 Forward/Reverse Common +12VDC Feedback (A) Frequency Back-Panel Terminal Strips (Wiring Connections): 13 14 15 16 17 18 19 20 21 22 23 24 TB1 12 1 A TB1 B Sensor Configuration Switches Output Span Adjustment Potentiometer Zero Offset Adjustment Potentiometer A 1 2 3 4 5 6 7 TB2 8 9 10 11 12 B 13 14 15 16 17 18 19 20 21 22 23 24 Page - 6 AC Line AC Neutral AC Ground Diode Protect N/C Common Low Speed Drive Enable Batch Complete Deviation Chassis Ground Shield Cut - Signal At Position Common Common Chassis Ground Shield TXDRXD+ RXD- Chassis Ground Shield TXD+ N/A Isolated Speed Command Output 0-10V Isolated Common TB2 (Version 2.0) (00.08.22) WIRING AND I/O FUNCTION (cont.): Proper Wiring Methods: 1) All Control Signals must use shielded cable. This means all wiring except for AC input power to the MicroLength must be shielded. The shield must be tied at the receiving end only to signal common. 2) Never use a shielded cable with unused conductors. The unused conductors act as antennas and will corrupt your signals. Attempting to tie them to ground or other signals just creates different antenna configurations. - (In fact, in many cases unshielded wire with the proper number of conductors would have received less electrical noise, than a shielded cable with unused conductors. However, don’t take this to mean it is alright to use unshielded signal wiring). Always insure that a shielded cable with the correct number of conductors is pulled. 3) All control signals must be separated from power wiring. Power wiring includes any AC or DC voltages with a current potential of greater than 1 amp or a voltage greater than 24 volts, such as 115 VAC, 230 VAC, 460 VAC, armatures, fields, and ignition wires. Do not bundle shielded cables and power wiring within the same Panduit, Conduit, or Wire Trays. 4) Do not run signal cables along high magnetic or electrostatic generators, such as motors, fans, contactors, igniters, etc. Aluminum shielded cable does not stop magnetic noise, and braided shielded cable only partially reduces magnetic noise. Neither can stop all noise or be a cure-all. Using shielded cable does not mean you can ignore proper signal routing techniques. Do not run feedback signal wires (encoders, Hall-effect sensors, magnetic pickups, etc.) along a motor case or in the same conduit as power to the motor. 5) An Earth Ground wire must be installed on microprocessor based controllers when it is specified. Do not rely on enclosure contact with the panel for earth ground. Earth ground is often used in noise rejection circuitry and is not just a safety factor. 6) Contactors, solenoids, and relay coils on the same AC power or in the same enclosure (panel) as the controller must be suppressed with a capacitor-resistor filter across the coil. These can be made with a 1KV capacitor and a 1/4 watt resistor in series, or they can be purchased in a pre-made package. Use a capacitance value of 0.1 uf or larger and a resistance value of 500 ohms or less. 7) When power is stepped down from a higher AC voltage for controllers, a cap-resistor network or other filter should be placed across the secondary. 8) After the above precautions have been taken to ensure clean power and control signals, do not route these lines alongside noisy power. Page - 7 (Version 2.0) (00.08.22) WIRING AND I/O FUNCTION (cont.): AC Power Connection: Power to the MicroLength is 115 VAC 50/60 Hz (standard) or 230 VAC (optional). Power input to the MicroLength should be as clean as possible so that the control circuitry is not exposed to spikes and other noise. Noise immunity is built into the unit, however, care should still be taken. Connect the AC power wires to these MicroLength input terminals: • AC Line wire = TB2-22 input terminal • AC Neutral wire = TB2-23 input terminal • AC Ground wire = TB2-24 input terminal AC Input Power Selection: FUSE 115VAC 230VAC Changing AC power on a MicroLength power board: - Remove the AC power board from the MicroLength chassis. - Set the voltage selection switch to the correct position (115 VAC or 230 VAC). - Replace with correct fuse (0.25 amp ‘fast blow’ for 115 VAC; 0.125 amp ‘fast blow’ for 230 VAC). - Re-install power board back into the MicroLength. - Change or remove voltage label on outside of MicroLength chassis. See drawing below: Connections to Variable Speed Motor Drive: The connection to the motor-drive must be a shielded twisted pair cable with the shield tied to the MicroLength. Connect these MicroLength output terminals to the drive’s inputs as follows: • Isolated Command output terminal TB2-2 = Connect to the drive’s input terminal that is normally connected to the wiper of the speed potentiometer. • Isolated Common output terminal TB2-3 = Connect to the reference common on the drive. Note: Isolated Command Output (a.k.a. Analog Output). Page - 8 (Version 2.0) (00.08.22) WIRING AND I/O FUNCTION (cont.): Feedback Encoder and MicroLength Compatibility: The MicroLength can accept encoders having these types of output signals: - NPN Open Collector - 3 wire (factory standard configuration) - PNP Open Collector - 3 wire - Magnetic pick-up - 2 wire - Logic Level. All sensors should have shielded cable with no unused conductors. Feedback Encoder Terminals: Standard MicroLength Operation without ‘Reverse-detection’: Connect the single-channel encoder wires to these MicroLength terminals: • Encoder Power wire = TB1-1 MicroLength encoder supply terminal (+12 Vdc) • Encoder Signal wire = TB1-2 Feedback ‘A’ Frequency input terminal • Encoder Common wire = TB1-5 Common terminal Optional MicroLength Operation with ‘Reverse-detection’: (See ‘Introduction \Details of Operation \Feedback Encoder Reverse-detection’ for more details). Connect the quadrature encoder power and ground wires to these MicroLength terminals: • Encoder Power wire = TB1-1 MicroLength encoder supply terminal (+12 Vdc) • Encoder Common wire = TB1-5 Common terminal Connect the quadrature encoder Chan A and Chan B wires to the optional external ‘Quad Encoder Input Adapter’: • (See the Quad Encoder Input Adapter’s instruction sheet for details). Connect the optional external ‘Quad Encoder Input Adapter’ outputs to these MicroLength terminals: • Adapter Count-Up Signal output = TB1-2 Feedback ‘A’ Frequency input terminal • Adapter Count-Down Signal output = TB1-3 Feedback ‘B’ Frequency input terminal Sensor Configuration Switches: Set the Sensor Switches (pull-up/down resistors) according to the encoder’s signal output type. See table below: Encoder signal output type Sensor Switch Settings Sensor Switch Settings (see notes 1 and 2 below) 12 11 10 9 8 7 6 5 NPN Open Collector OFF OFF OFF ON n.a. n.a. n.a. n.a. PNP Open Collector OFF OFF ON OFF n.a. n.a. n.a. n.a. Zero-Crossing (Mag) ON ON ON OFF n.a. n.a. n.a. n.a. Logic Level OFF OFF OFF OFF OFF OFF OFF OFF Note: When sharing signals never use more than one pull-up resistor. NPN Open Collector = 2.2K pull-up to +12V, Trigger point at 2.5V PNP Open Collector = 2.2K pull-down to common, Trigger point at 2.5V Zero Crossing (Mag) = 50mV minimum peak, Trigger point at 50mV Logic Level = Trigger point at 2.5V Notes: 1) When using the optional ‘Quad Encoder Input Adapter’ for ‘Reverse-detection’, set all the MicroLength Sensor Switches 5 through 12 to the OFF position. This because the Quad Encoder Input Adapter’s Count-Up and Count-Down output signals are Logic Level type. 2) For standard operation without ‘Reverse-detection’, only the MicroLength Sensor Switches 9 through 12 must be set accordingly (for standard operation, switches 5 through 8 are not applicable - n.a.- and are ignored). 3) Sensor Switches 1 through 4 exist on the MicroLength, but they are ignored in all cases. Page - 9 (Version 2.0) (00.08.22) WIRING AND I/O FUNCTION (cont.): Schematic of the MicroLength’s Frequency Inputs and External Switch Inputs internal circuitry, containing the pull-up and pull-down resistors and their corresponding Sensor Configuration Switches: MICROLENGTH INPUTS Switch Inputs +12V Frequency Inputs +12V +12V Pull-up Resistor 2.2K TB1-1 1M 2.2K SW5,9 TB1-2,3 10K 10K Pull-down Resistor 10K 2.2K SW7,11 SW8,12 TB1-5 10K 0.0047uf 0.047uf +5V SW6,10 100 220pf Page - 10 (Version 2.0) (00.08.22) WIRING AND I/O FUNCTION (cont.): Basic External Switch Inputs: The basic Run, Stop, Jog, and E-Stop commands are available via external switch inputs. (Run, Stop, and Jog are also available from the front-panel keypad). Run: The ‘Run’ external switch input functions as the run-cycle start command. When this ‘normally open, momentary closed’ input is closed, the MicroLength then begins the run-cycle. It continues to run until the Set Point length is reached. (The external Run switch is wired between TB1-21 (Run) and Common). Stop: The ‘Stop’ external switch input functions as a run-cycle interrupt command (a.k.a. interrupt-stop). When this ‘normally closed, momentary open’ input is opened, the MicroLength ramps the motor/encoder to a stop. While waiting in ‘interrupt-stop’ mode a number of events can happen: - If a Run command is given, then the MicroLength ramps the motor/encoder back up to maximum speed (provided there remains sufficient distance left in the run-cycle) and completes the run-cycle. - If a Jog command is given, the MicroLength jogs the motor/encoder at jog speed, and keeps track of the length. - If the UP-ARROW key is pressed or the End Cycle external switch input is closed, then the run-cycle aborts and is not counted by either the cycle counter or batch counter. The MicroLength then returns to “READY” mode. (The external Stop switch is wired between TB1-22 (Stop) and Common). Note: If the back-panel Stop input is not used, jumper TB1-22 to Common (factory installed). E-Stop: The ‘E-Stop’ external switch input functions as an immediate stop (0 volts) command to the drive. The E-Stop function is only available via the MicroLength back-panel. When this ‘normally closed, momentary open’ input is opened, the MicroLength slams its Analog Output to 0 volts. When the E-Stop is activated, then the run-cycle aborts and is not counted by either the cycle counter or batch counter. (The external E-Stop switch is wired between TB1-24 (E-Stop) and Common. Note: If the back-panel E-Stop input is not used, jumper TB1-24 to Common (factory installed). Jog: The ‘Jog’ external switch input functions as the motor/encoder jog command. When this ‘normally open, sustained closed’ input is closed, the MicroLength outputs the Var11 Jog Output Percent voltage to the drive, and does so until the Jog input is opened. The Jog command can be given while in the “READY” mode, or at an ‘interrupt-stop’: - When a Jog command is given, the length count is NOT reset to zero, but rather the MicroLength keeps track of the distance traveled. This so extra length can be added at the end of a cycle, or at an ‘interrupt-stop’ if needed. (The external Jog switch is wired between TB1-19 (Jog) and Common). Other External Switch Inputs: Certain non-basic operational features of the MicroLength can be done via external switch inputs. Run at High Speed: The ‘Run at High Speed’ external switch input functions as a command to manually run the motor/encoder at high speed. When this ‘normally open, sustained closed’ input is closed, the MicroLength ramps its Analog Output to the Var09 High Speed Output Percent voltage and runs the motor/encoder at High Speed until the input is opened. The manual ‘Run at High Speed’ command can be given while in the “READY” mode, or during a run-cycle: - If the manual ‘Run at High Speed’ command is given while in the “READY” mode, then the length count is cleared and the length begins counting from zero. - If the manual ‘Run at High Speed’ command is given while a run-cycle is underway, then the length count is NOT cleared and the length continues counting. Also, the present run-cycle aborts (is not counted by either the cycle counter or batch counter), and control is handed-off on-the-fly to the manual ‘Run at High Speed’ mode. (The external manual ‘Run at High Speed’ switch is wired between TB1-18 (Run at High Speed) and Common). Page - 11 (Version 2.0) (00.08.22) WIRING AND I/O FUNCTION \External Switch Inputs: (cont.): Forward/Reverse: The ‘Forward/Reverse’ external switch input functions as the Analog Output voltage polarity selection input: - When this input is open, the Analog Output polarity is 0 to +10 Vdc, (i.e., Positive = Forward). - When this input is closed, the Analog Output polarity is 0 to –10 Vdc, (i.e., Negative = Reverse). If the ‘Fwd/Rev’ input changes state during a run-cycle, then the input is ignored until after the run-cycle completes. (The external ‘Forward/Reverse’ switch, or hard-wire, is wired between TB1-13 (Forward/Reverse) and Common). Note: The ‘Fwd/Rev’ function is not intended for using the MicroLength as a bi-directional length controller, but rather only for jogging or creeping in the opposite direction if need be. Batch Reset: The ‘Batch Reset’ external switch input functions as a command to reset the Batch Total and Cycle Counter. When this ‘normally open, momentary closed’ input is closed, the Var23 Batch Total and the Var24 Cycle Counter are both reset to 0, and the Batch Complete alarm output is turned OFF. (The external Batch Reset switch is wired between TB1-15 (Batch Reset) and Common). Local/Remote: The ‘Local/Remote’ external switch input functions as the Local or Remote selection input: - When this input is open, the Local mode is selected. This means that all commands are given to the MicroLength via the front-panel keypad and back-panel inputs. - When this input is closed, the Remote mode is selected. This means that the MicroLength is under computer control over the RS422 serial communication lines. All front-panel keypad and back-panel external input commands are ignored, except E-STOP and those enabled during remote mode via Var47. (The external Local/Remote switch, or wire, is wired between TB1-10 (Local/Remote) and Common). Keypad Lockout: The ‘Keypad Lockout’ external switch input functions as a keypad security ON or OFF input. - When this input is open, keypad security is OFF (disabled). All keypad functions are accessible. - When this input is closed, keypad security is ON (enabled). Access to certain keypad functions are denied, as determined via the Keypad Lockout Variable Var18. (The external Keypad Lockout switch, or wire, is wired between TB1-12 (Keypad Lockout) and Common). End Cycle: The ‘End Cycle’ external switch input functions as an ‘abort run-cycle while at interrupt-stop’ command. If while at an ‘interrupt-stop’ this ‘normally open, momentary closed’ input is closed, then all the following happen: - The run-cycle aborts and is not counted by either the cycle counter or batch counter. - The MicroLength returns to “READY” mode. - The length count is cleared (and the length begins counting from zero on the next run-cycle). (The external End Cycle switch is wired between TB1-6 (End Cycle) and Common). Note: The UP-ARROW key on the keypad also serves this same function, if pressed while at an ‘interrupt-stop’. Set Point 1(3)/2(4) Select and Set Point 3 & 4 Enable: The two external switch inputs labeled ‘Set Point 1(3)/2(4)’ and ‘Set Point 3 & 4 Enable’ work together as a function to select which Set Point 1, 2, 3, or 4 is the active Set Point. These switch inputs select the active Set Point according to this table: Set Point 1(3)/2(4) input open closed open closed Set Point 3 & 4 Enable input open open closed closed Active Set Point Set Point 1 Set Point 2 Set Point 3 Set Point 4 (The external ‘Set Point 1(3)/2(4)’ switch is wired between TB1-16 and Common). (The external ‘Set Point 3 & 4 Enable’ switch is wired between TB1-9 and Common). Page - 12 (Version 2.0) (00.08.22) WIRING AND I/O FUNCTION (cont.): Status and Alarm Outputs: The MicroLength has six transistor alarm outputs: - The alarm outputs are: Drive Enable, At Position (cycle complete), Deviation from Set Point, Cut-Signal, Running at Low Speed, and Batch Complete. - The outputs are Open Collector NPN transistors rated for 50 Vdc, 250 mA max current, and 0.3 max watts. - The outputs are activated based on fixed or programmable events. - There is a diode protection circuit built into the MicroLength. - The outputs can be wired directly to the MicroLength’s own external switch inputs. - To use these outputs with any external device (i.e., relays, lamps, horns, etc), a separate, external DC power supply should be used (instead of using -and loading down- the MicroLength’ s on-board +12 Vdc encoder power supply). If an alarm output is to be used to activate a non-inductive load, then wire-up as follows: - Tie the negative terminal of the external DC supply to a MicroLength common terminal. - Then connect the load device between the positive terminal of the external DC supply and the desired MicroLength alarm output terminal. If an alarm output is to be used to activate a relay or other inductive load, then in order to avoid damage to the MicroLength’s alarm output circuit, the external DC power supply should always be run in parallel with the Diode Protection terminal TB2-20, as explained here: (See example/drawing below). - Tie the positive terminal of the external DC supply to the Microlength Diode Protect terminal TB2-20. - Tie the negative terminal of the external DC supply to a MicroLength common terminal. - Then connect the inductive load device between the positive terminal of the external DC supply and the desired MicroLength alarm output terminal. Example: Connections for driving a relay with a MicroLength Alarm Output. +VDC TB2-20 RELAY COIL INTERNAL TO MICROLENGTH MICROLENGTH ALARM OUTPUT TERMINAL (Ex: TB2-19) MICROLENGTH COMMON TERMINAL (Ex: TB2-18) Page - 13 External Power Supply 50VDC max COMMON (Version 2.0) (00.08.22) WIRING AND I/O FUNCTION \Status and Alarm Outputs (cont.): Low Speed (TB2-19): This output activates (turns ON) when the MicroLength begins its decel ramp from Var09 High Speed. This output deactivates (turns OFF) after the Creep Time/Speed portion of the run-cycle is complete. This output also activates while jogging. Batch Complete (TB2-17): This output activates (turns ON) at the end of a run-cycle (after the Var12 Settle-Time expires), if the number of cycles ran (Var24 Cycle Count) equals the Var06 Batch Set Point. After this output turns ON, the Var24 Cycle Count is reset to 0 for the next batch, and the Var23 Batch Total counter is incremented. This output then deactivates (turns OFF) when any of the following events happen: - At the start of the next run-cycle. - If the Batch Reset external switch input is closed. - If Var51 is sent the value of 1 via the RS422 serial communications link. - A Jog command is given. Drive Enable (TB2-16): The Drive Enable output is used to enable the motor drive controlled by the MicroLength. This output activates (turns ON) on a Run, Jog or a manual ‘Run at High Speed’ command. This output deactivates (turns OFF) in one of three different ways, following a normal stop condition. Just exactly when this output turns OFF, is controlled by the Var22 Drive Enable variable. (See Programming Specifics, Status and Alarm Output Variables - Var22). The Drive Enable output immediately deactivates upon an E-Stop command. Deviation (TB2-14): The Deviation output activates (turns ON) at the end of a run-cycle (after the Var12 Settle-Time expires), if the actual length of the run-cycle is more than ±Var21 Deviation pulses away from the desired Set Point length. This output then deactivates (turns OFF) when any of the following events happen: - At the start of the next run-cycle. - A Jog command is given. (See Programming Specifics, Status and Alarm Output Variables - Var21). Note: You can use the Var28 Resolution variable to check the length of one encoder pulse of travel, defined in your ‘User units’. At Position (TB2-11): This output activates (turns ON) at the end of a run-cycle (after the Var12 Settle-Time expires). (This output indicates only that the run-cycle is complete. This output should not be relied upon as an indication that the run-cycle has stopped ‘dead-nuts-on’ at exactly the Set Point length). This output then deactivates (turns OFF) when any of the following events happen: - At the start of the next run-cycle. - A Jog command is given. Page - 14 (Version 2.0) (00.08.22) WIRING AND I/O FUNCTION \Status and Alarm Outputs (cont.): Cut-Signal (TB2-13): Note: MicroLength version 2.0 uses this alarm output TB2-13 as a Cut-Signal output function. This is different than MicroLength version 1.0, which uses this alarm output TB2-13 as a High Speed alarm function. In MicroLength version 2.0 the Cut-Signal output can be used after the run-cycle has ended, to start/stop an external cutting operation, etc,. (See Programming Specifics, Status and Alarm Output Variables - Var38 and Var39). This Cut-Signal output normally activates (turns ON) at the end of a run-cycle, but only after both the Var12 Settle-Time and the Var38 Cut-Delay time have expired. This Cut-Signal output then normally deactivates (turns OFF) when the Var39 Cut-Time expires. However due to abnormal cases, the Cut-Signal alarm output operation is subject to these following restrictions: a) The Cut-Signal alarm output is overridden (either kept OFF, or turned OFF prematurely) if any of the following actions happen during the Cut-Signal operation (i.e., during the Var38 Cut-Delay time or the Var39 Cut-Time): - User gives an ‘E-Stop’, ‘Run’, ‘Jog’, or a manual ‘Run at Hi-speed’ command via external switch inputs. Note: Because of this, the cut-signal output may not be directly usable in applications having a continuous ‘Run’ command (via a closed contact on the TB1-21 external switch input), since the continuous ‘Run’ command continually overrides the cut-signal operation. - User gives a ‘Run’, or ‘Jog’ command via the front-panel keypad. - User gives an ‘E-Stop’, or ‘Run’ command via serial communications. - User presses the front-panel ‘2nd Function’ key. - User gives a ‘Factory-Default Software Reset’ command via serial communications. b) The Cut-Signal output can only turn ON after a ‘completed’ run-cycle. If the run-cycle is aborted (due to any one of the six run-cycle abort events) then the Cut-Signal output remains OFF. (See Appendix D for details on the six abnormal run-cycle abort events). General notes about all Status and Alarm Outputs: - All alarm outputs are OFF while resting at a run-cycle ‘interrupt-stop’. - All alarm outputs turn OFF when Diagnostic Five (alarm output test) is entered. - All alarm outputs turn OFF when a software reset is done (via Power-up with Software Reset; via Diagnostic Seven Software Reset; or via Factory-Default Software Reset via serial communications). Page - 15 (Version 2.0) (00.08.22) SECTION IV MicroLength Set-up Procedure: This procedure gives the correct ‘flow’ in how to set-up the MicroLength programming. (For details on individual variables see the appropriate section under Programming Specifics). After you have wired-up the MicroLength (according to SECTION III: WIRING AND I/O FUNCTION), then follow the steps in this procedure to set-up the MicroLength programming. 1) Calibrating the Analog Output (i.e., using Diagnostic Nine): The first (and most important) step in setting-up the MicroLength is calibrating the Analog Output (a.k.a. Isolated Command Output) to the drive/motor. Since the MicroLength is an ‘open-loop’ speed controller, it is absolutely essential the Analog Output be properly calibrated. A properly calibrated Analog Output ensures the feedback encoder actually runs at the design goal maximum RPM when the Analog Output is at the maximum of 99%. This greatly improves run-cycle accuracy and repeatability. REPEAT: Calibrating the Analog Output to the drive/motor, is the most important thing the MicroLength user can do to ensure good run-cycle accuracy and repeatability!! If you do not correctly calibrate the Analog Output, you can almost guarantee you will experience poor run-cycle accuracy and repeatability (and much frustration)!! Follow these steps (in order) to correctly calibrate the Analog Output: a) In this first step to calibrating the Analog Output the user must: - Var04 Feedback PPR: Enter the pulse per revolution of your feedback encoder into Var04. - Calculate or know beforehand the design goal maximum RPM you expect the drive/motor to spin the feedback encoder at, during the process run-cycle. This is the RPM value you will calibrate the Analog Output to in step (f) below. (This is also your Var05 value, but you don’t need to enter it yet). Note: This maximum RPM value must be a well calculated value, and not just a wild guess. (DO NOT use the maximum RPM rating on the motor’s nameplate, unless the feedback encoder is attached to the motor shaft and your design goal is to reach the nameplate RPM during the run-cycle). b) Select the polarity of the Analog Output voltage (to match your drive) using the Forward/Reverse input: - Open = Positive (i.e., Forward, 0 to +10 Vdc). - Closed = Negative (i.e., Reverse, 0 to –10 Vdc). c) Access Diagnostic Nine (Digital Potentiometer) by pressing the 2ND FUNC key, followed by the ‘9’ key: - (The lower display shows "Pot% 00"). d) While at "Pot% 00", adjust the Zero Offset potentiometer (located on the back of the MicroLength) until the motor/encoder just begin to creep, then back off until they stop creeping. e) Press and hold the UP-ARROW key until the lower display reads "Pot% 99". - The motor/encoder should be turning. - The upper display shows feedback encoder speed in RPM. f) Adjust the Output Span potentiometer (located on the back of the MicroLength) until the upper display shows your design goal maximum feedback encoder RPM. - (In case your design goal RPM is not quite reached, make note of the RPM actually obtained, so you can use that value in step (i) below). g) Press and hold the DOWN-ARROW key until the lower display reads "Pot % 00." h) Press the 2ND FUNC key to exit the Diagnostic Nine Digital Potentiometer mode. - The lower display shows “STOPPING” then “READY”. i) With the MicroLength back in the “READY” mode, go to Var05 and enter into it the actual RPM value observed in step (f) above. Page - 16 (Version 2.0) (00.08.22) MicroLength Set-up Procedure (cont.): 2) Programming the System Set-up Variables: a) Var04 Encoder PPR and Var05 MAX Encoder RPM: - These two set-up Vars already programmed when the Analog Output calibration procedure was done. b) Var11 Jog Speed Output Percent (how fast to run while jogging): - For initial set-up try 10 (i.e. 10%). - As an experiment, try different values for Var11, and find the slowest speed the drive can smoothly jog the motor/encoder. This knowledge will be helpful when choosing a value for Var10 later on. c) Var07 Acceleration Time and Var08 Deceleration Time (how fast to accelerate/decelerate the encoder): - Var07 and Var08 are generally limited by the system’s inertia restraints, since the MicroLength can’t ‘force’ the system any harder than the motor-drive is capable of starting and stopping the system’s mass. d) Var09 High Speed Output Percent (how fast to run during the peak of the run-cycle): - For initial set-up, set this value to 100 (i.e. 100%). This tells the MicroLength to shoot for 100% of the Var05 Max RPM speed. Var09 can be lessened later if necessary. e) Var10 Creep Speed Output Percent (how fast to run during the ‘creep’ portion of the run-cycle): - Generally, the slower the motor can creep, the more accurate the MicroLength can perform. However, there is a limit to how slow the drive can turn the motor, before the motor binds, cogs, and jerks at slow speed. Set Var10 as low as possible, but yet high enough to avoid ill motor performance. (Use different values of Var11 Jog Speed, to test how slow the drive can still turn the motor smoothly). f) Var29 Kerf Addition (automatically account/compensate cycle length for material lost during cutting): - If your process uses no cutting operation, or you do not need to account for material lost during cutting, then enter 0 into Var29. - If your process uses a saw blade, etc, to cut a material between run-cycles, and you need to account for the amount of material removed during a cut, then enter into Var29 the width of the material removed from the cut. Note: Var29 uses the same units of ‘length’ that Var01 and the length Set Points use, so you may want to come back to Var29 after setting-up Var01, if you do not know your ‘User Units’ yet. (See Programming Specifics, System Set-up Variables for details about any of these set-up variables). 3) Programming the Reference Length Variables: These reference variables tell the MicroLength how feedback encoder revolutions relate to production amounts and length Set Points, as defined in ‘User Units’. a) Var01 Reference Length: - Decide upon a certain amount of product to use as your ‘reference amount’. It could be any amount such as: a whole number like 1 foot, or a mixed number like 10.567 grams, etc. Whatever amount of product you choose as your reference length (defined in your ‘User Units’), enter that value into Var01. b) Var02 Reference Length in Whole Revolutions: - Enter into Var02 the number of whole revolutions your feedback encoder must turn to produce the amount of product equal to (or just less than) your chosen Var01‘reference amount’. c) Var03 Reference Length in Additional Pulses (remaining partial revolutions): - Enter into Var03 the number of additional pulses your feedback encoder must turn for the remaining small amount of product to add (to the Var02 portion) in order to reach the total equal to your chosen Var01‘reference amount’. (See Programming Specifics, Reference Length Variables for details about any of these reference variables). Notes: - Auto-Programming (Diagnostic Eight) can be used to acquire values for Vars 01, 02 and 03. (See next page for how to use Diagnostic Eight). - After programming the reference variables (either on your own or by using Diagnostic Eight), you can check the resolution of the system by looking at Var28. Var28 gives the resolution of the system, by displaying how many of your ‘User Units’ (or fractional parts of your ‘User Units’) there are in one feedback encoder pulse. Since the MicroLength can control down to a minimum of 1 pulse, Var28 is the smallest unit of length the MicroLength can control to (the MicroLength cannot control to any ‘User unit’ value tighter than the value shown in Var28). It is not recommended to attempt finer accuracy than the feedback encoder and system are equipped to resolve. Page - 17 (Version 2.0) (00.08.22) MicroLength Set-up Procedure \Programming the Reference Variables (cont.): Auto-Programming (Diagnostic Eight): Diagnostic Eight is designed to assist the user in the initial set-up of the MicroLength, by automatically assigning values to the Reference Variables Vars 01, 02 and 03, that properly correspond to the user’s chosen/measured ‘reference amount’ of product. Follow these steps (in order) to correctly perform the Auto-Programming feature: a) Enter (or verify) your feedback encoder pulse per revolution (PPR) value into Var04. b) Access Diagnostic Eight by pressing the 2ND FUNC key, followed by the ‘8’ key: - The lower display quickly shows “SET-UP”, then followed by “SetUpRev”. c) Press and hold the UP-ARROW key to increase the Analog Output and start the motor/encoder turning: - The longer you hold-in the UP-ARROW key, the faster the motor/encoder turns. Since speed is not important here, let go of the UP-ARROW key as soon as the motor/encoder run smoothly. - The lower display continues to show “SetUpRev”. - The upper display shows the number of encoder revolutions traveled since the encoder first started turning. d) Continue running the motor/encoder as your process builds up product. e) As your process approaches your desired ‘reference amount’ of product, press and hold-in the DOWN-ARROW key to bring the motor/encoder to a stop. Note: The length run does NOT have to be exactly equal to your desired ‘reference amount’ of product, just being fairly close will be sufficient. - The lower display continues to show “SetUpRev”. - The upper display shows the number of encoder revolutions traveled (corresponding to the amount of product produced) during this Auto-Programming mode. f) With the motor/encoder stopped, press the ENTER key: - The lower display shows “RefLngth”, for reference length. - The upper display shows the previous value that was (and still is) in the Var01 Reference Length variable, (pay no attention to the numbers in the upper display at this time). g) Measure the actual length, or amount of product produced, using your ‘User Units’: - This is now your actual, and official ‘reference amount’ of product. h) With the lower display still showing “RefLngth”, use the number and decimal point keys on the MicroLength front-panel, to enter in your measured ‘reference amount’ of product: - You can enter in the value of your measured ‘reference amount’, with anywhere from five to no digits following the decimal point. (The MicroLength accepts a decimal point at up to 5 decimal places). - If you accidentally entered wrong numbers, or placed the decimal point in the wrong location, DO NOT press the ENTER key, but rather just enter the numbers again the way you want them to appear. i) When the upper display shows exactly how you want your measured ‘reference amount’ to read, then press the ENTER key. - The lower display shows “SET-UP”. - The upper display once again shows the number of encoder revolutions traveled (corresponding to the amount of product produced) during this Auto-Programming mode. - Internally the MicroLength places your measured ‘reference amount’ of product into Var01. - Internally the MicroLength places the whole number of encoder revolutions traveled during this auto-programming mode into Var02. - Internally the MicroLength places any remaining partial number of encoder revolutions traveled (defined in encoder pulses) during this auto-programming mode into Var03. j) With the lower display showing “SET-UP”, exit the Diagnostic Eight Auto-Programming mode, by pressing the 2ND FUNC key: - The MicroLength exits the Auto-Programming mode, and the lower display shows “READY”. Note: Once back in the “READY” mode, if you are curious, you can check (or verify) that your measured ‘reference amount’ of product is in Var01 Reference Length. You can also check on what values the MicroLength has placed into your Var02 Whole Revolutions and Var03 Additional Pulses variables. Page - 18 (Version 2.0) (00.08.22) MicroLength Set-up Procedure (cont.): 4) Programming the Display Variables: The Display Variables are used to tell the MicroLength what information to display: Var17 Display Selection (select the data you want shown in the upper and lower displays). The choices are: - ‘Length’, ‘User Units / Second’, ‘User Units / Minute’, ‘Batch Count’, ‘Cycle Count within present Batch’. Var16 User Unit Label (select the ‘User Unit’ label you want inserted into the lower display): - ‘User Units’ are: Feet, Yards, Gallons, Meters, etc. - If your desired ‘User Units’ are not in the Var16 list, then use Diagnostic Zero – Custom User Unit Label Programming to create your own ‘User Unit’ label. (See Programming Specifics, Display Variables – Var17, Var16, and Diagnostic Zero). 5) Programming the Status and Alarm Output Variables: These variables determine the operation of the Deviation, Drive Enable, and Cut-Signal alarm outputs. Var21 Deviation Alarm. Select your desired ± Deviation Alarm window, measured in encoder pulses. Var22 Drive Enable. Select your desired Drive Enable output operation: - Drive Enable is normally set at the default setting of 000001. Var38 Cut-Delay time. If using the Cut-Signal output, enter your desired delay time (at the end of a run-cycle) before turning ON the Cut-Signal output. Var39 Cut-Time. If using the Cut-Signal output, enter your desired time to hold ON the Cut-Signal output. (See Programming Specifics, Status and Alarm Output Variables – Vars 21, 22, 38, 39). 6) Programming the Batch Set-up Variable: This variable determines how many run-cycles there are in a Batch. Var06 Batch Set Point. Enter your number of ‘run-cycles per batch’. (See Programming Specifics, Batch Set-up and Batch Monitor Variables – Vars 06, 23, 24). 7) Programming the Length Set Points: Enter your length Set Point(s). Is your length Set Point long enough for proper MicroLength operation? The ‘active length Set Point plus any Var29 Kerf Addition’ must be greater or equal to the Var35 MinSetPt: - If not, then try smaller values in Var09 High Speed Output Percent, until the Var35 MinSetPt value becomes smaller than your ‘length Set Point plus any Var29 Kerf Addition’. - You can also try smaller values in Vars 07, 08, 10 or 13 (but lessening Var09 is probably the easiest). Give the MicroLength a RUN command (via either the front-panel ‘Run’ button, the back-panel ‘Run’ external switch input, or via the serial RS422 link). The MicroLength should run the cycle, and the lower display should be alternating between your Var17 Display Selection and the message “LEARNING”. After the first run-cycle is done, try another. If the MicroLength’s lower display gives the message “HiSpdErr” (high speed error), then Var09 High Speed was not reached during the last run-cycle. Try lessening Var09 some more, then try running again. Continue lessening Var09 until repetitive run-cycles can be accomplished. (See Programming Specifics, Entering Length Set Points). (See Programming Specifics, System Performance Monitor Variables – Var35). (See Appendix D for details on Normal/Abnormal Run-Cycles, and “HiSpdErr” or other error messages). Page - 19 (Version 2.0) (00.08.22) MicroLength Set-up Procedure (cont.): 8) Programming the Fine-Tuning Variables: The final step to get up and running is to fine-tune the MicroLength. (Some applications will not require changes to these variables as the default values are sufficient enough). Var12 Settle-Time. Run and observe your process. Enter a sufficient time to allow the system to settle. Note: If Var12 is too small, resulting in the motor/encoder not coming to a complete rest before the MicroLength’s correction-algorithm checks the error and makes calculations for the next run-cycle, then poor run-cycle accuracy and repeatability may be experienced. Var13 Ideal Creep Time. Run and observe your process. Enter a sufficient time to allow the feedback encoder’s speed a chance to stabilize, catch-up and track the MicroLength's Analog Output. This allows the MicroLength to regain complete control during the creep speed portion, before reaching the Set Point length. Notes: - When tuning Var13, allow several run-cycles for each new Var13 value. (Because the MicroLength goes through the system’s inertial behavior ‘LEARNING’ process each time Var13 is changed). - If Var13 is too small, then the MicroLength’s Analog Output may stop (reach 0 volts) before the feedback encoder stops: in a sense the MicroLength loses control of the system. As a result, poor run-cycle accuracy and repeatability will be experienced. - In an extreme ‘worse case situation’, if the inertial energy of the system is quite large and if Var13 is too small, then the feedback encoder will be at significant speed while the Analog Output is already at 0 volts. (Obviously, the MicroLength will not be able to stop this type of run-cycle very accurately!!). - If the system's drive/motor/encoder track the MicroLength's Analog Output well, then less Var13 is necessary. - (See ‘Introduction \Summary of Operations’ and ‘Introduction \Details of Operations \Open-loop Control Issues’ for more details on MicroLength control). Var14 Integral Start. Run and observe your process. Set as desired. Var15 Integral Correction. Run and observe your process. Set as desired. (See Programming Specifics, Fine-Tuning Variables - Vars 12, 13, 14, 15). 9) Enabling Keypad Lockout: After programming the MicroLength, setting and enabling the Keypad Lockout feature is recommended: - Var18 Keypad Lockout. Set Var18 according to your desired lockout protection. - Enable ‘lockout’ by closing (via switch or hard-wire) the external switch input TB1-12 to Common. (See Programming Specifics, System Set-up Variables – Var18). Page - 20 (Version 2.0) (00.08.22) SECTION V - PROGRAMMING SPECIFICS Entering Length Set Points: Length Set Points refer to the amount of motor/encoder travel and may relate to distance, length, volume, weight, etc. The value of the ‘active’ length Set Point can be changed to any length, by pressing the SET POINT key, entering a new length using the number and decimal point keys, and then pressing the ENTER key. The value of a ‘non-active’ length Set Point, is changed by pressing the SET POINT key, and then the UP or DOWN-ARROW key until the desired Set Point name is displayed in the lower display. Then enter a new length using the number and decimal point keys, and then pressing the ENTER key. The ‘active’ length Set Point is selected by the back-panel ‘Set Point 1(3)/2(4)’ and ‘Set Point 3 & 4 Enable’ switch inputs. (See ‘WIRING AND I/O FUNCTION \External Switch Inputs’ for details on how the ‘active’ Set Point is selected). The front-panel LEDs indicate which length Set Point is active, as shown by this table: Front-panel Set Point LEDs SETPT 1 = ON SETPT 2 = ON both SETPT 1 and 2 = ON both SETPT 1 and 2 = OFF Active Set Point 1 2 3 4 Notes about entering length Set Points: 1) The MicroLength runs the cycle only if the ‘active length Set Point plus any Var29 Kerf Addition’ is greater or equal to the Var35 MinSetPt value. (See Prog. Specifics, System Performance Monitor Variables – Var35). 2) The MicroLength must be stopped when selecting a new active Set Point or when changing the value of the active Set Point: - External selections of the active set point (via TB1-16 or TB1-9 external switch inputs) are ignored during a run-cycle or while waiting for the Var12 Settle-Time to expire after a run-cycle. The MicroLength confirms the new active set point selection only after the present run-cycle finishes. (Ex: Changing from SETPT 1 to SETPT 3 during a run-cycle, is not recognized until the Microlength completes the present run-cycle). - The front-panel SET POINT key is locked-out during a run-cycle or while waiting for the Var12 Settle-Time to expire after a run-cycle (to prevent changing the value of the active Set Point via the keypad during a cycle). - Any changes in the value of the active set point via the RS422 link are ignored during a run-cycle or while waiting for the Var12 Settle-Time to expire after a run-cycle. The MicroLength recognizes the new active set point value only after the present run-cycle finishes. (See ‘Serial Communications \Using the Serial Protocol \Message Type = 0 \Command Type = 4’ for details on changing the active Set Point via the RS422 link). Entering Variables: Programming the MicroLength is done by entering data into a menu of variables. Only the variables that affect operation of the unit as it relates to the application must be programmed. Upon power up, the MicroLength displays "READY" on the lower display. This indicates that the MicroLength is ready for operation or for programming. To program a Variable: 1) Press the VAR key on the front-panel keypad: - The lower display prompts you for a Var number, and the upper display’s two right-most characters read ‘00’. 2) Use the number keys to enter the desired variable number, then press the ENTER key to access the variable: - Before the ENTER key is pressed, both the upper and lower displays echo the variable number entered. - After the ENTER key is pressed (and the variable accessed), the upper display shows the value of the variable accessed, and the lower display shows the name of the variable accessed. Note: If unsure of a variable’s number, press the UP / DOWN ARROW keys to scroll through the variable menu. (When scrolling, the upper display shows the variable’s number, while the lower display shows the variable’s name. To access a variable when scrolling, press the ENTER key while the desired variable is displayed). 3) Use the number keys to enter the data (into the accessed variable), then press the ENTER key when finished. - Note: A decimal point cannot lead an entry; the decimal place must be preceded by at least a 0 (zero). 4) After the ENTER key is pushed, the display prompts for another variable number. If there is no other variable data to enter, press the VAR key to return the MicroLength to the “READY” mode. Page - 21 (Version 2.0) (00.08.22) PROGRAMMING SPECIFICS \List of MicroLength 196 Variables: Var # Variable Name Units (if any) Type of Variable Var01 Reference Length user defined unit Reference Length * Var02 Reference Length Whole Revolutions revolutions Reference Length * Var03 Reference Length Additional Pulses pulses Reference Length * Var04 Feedback PPR pulses/rev System Set-up * Var05 Feedback RPM @ 99% Output RPM System Set-up * Var06 Batch Set Point run-cycles/batch Batch Set-up Var07 Acceleration Time seconds System Set-up * Var08 Deceleration Time seconds System Set-up * Var09 High Speed Output Percent % System Set-up * Var10 Creep Speed Output Percent % System Set-up * Var11 Jog Speed Output Percent % System Set-up Var12 Settle Time seconds Tuning Var13 Ideal Creep Time seconds Tuning * Var14 Integral Start pulses Tuning Var15 Integral Correction Tuning Var16 User Label Display Var17 Display Selection Display Var18 Keypad Lockout System Set-up Var19 Node Address Serial Comm. Set-up Var20 Baud Rate Serial Comm. Set-up Var21 Deviation Alarm pulses Alarm Output Var22 Drive Enable Alarm Output Var23 Batch Total batches (batch monitor only) Var24 Cycle Count run-cycles (batch monitor only) ** Var25 Feedback Frequency Hz (system monitor only) Var26 Creep Speed Time seconds (system monitor only) Var27 Position Error pulses (system monitor only) Var28 Resolution user units/pulse (system monitor only) Var29 Kerf Addition user units System Set-up Var30 Stop Correction Pulses pulses (system monitor only) Var31 Decel Correction Pulses pulses (system monitor only) Var32 Output Creep Time seconds (system monitor only) Var33 Last Cycle High Output % % (system monitor only) Var34 Last Cycle High RPM RPM (system monitor only) Var35 Minimum Set Point Length user units (system monitor only) Var38 Cut-Delay Time seconds Alarm Output Var39 Cut-ON Time seconds Alarm Output Var47 Switch Enable in Remote Serial Comm. Set-up Var48 Buffer Error (monitor only) Var49 New Set Point (serial only) user units (serial monitor only) Var50 Serial Status (serial only) (serial monitor only) Var51 Clear Batch Counter (serial only) Serial Comm. Control Var53 Forward or Reverse (serial only) Serial Comm. Control Var54 Set Point 1 (serial only) user units Serial Comm. Control Var55 Set Point 2 (serial only) user units Serial Comm. Control Var56 Set Point 3 (serial only) user units Serial Comm. Control Var57 Set Point 4 (serial only) user units Serial Comm. Control Var62 Display (serial only) (serial monitor only) Var63 Alarm Status (serial only) (serial monitor only) * Indicates that if value of variable changed, then MicroLength must perform the “LEARNING” process. ** Var24 is a monitor variable, but one which the user can still enter in a value. Var24 counts-up from zero, or from whatever number the user has entered into Var24 (as long as it is less than the Var06 value). Page - 22 (Version 2.0) (00.08.22) PROGRAMMING SPECIFICS (cont.): Variable Accessibility: a) List of ‘monitor only’ variables that user can only view, but not change: - Via the keypad: Vars 23, 25, 26, 27, 28, 30, 31, 32, 33, 34, 35, 48. - Via serial interface: Vars 19, 20, 23, 25, 26, 27, 28, 30, 31, 32, 33, 34, 35, 47, 48, 49, 50, 62, 63. Note: Vars 19, 20 and 47 are ‘monitor only’ via serial communications. When using serial communications, Vars 19, 20 and 47 must be set-up via the uL196 keypad before switching the uL196 to remote mode. b) List of variables that don’t use and will not accept decimal points: - Via the keypad: Vars 02, 03, 04, 06, 09, 10, 11, 14, 15, 16, 17, 18, 19, 20, 21, 22, 24, 47. - Via serial interface: Vars 02, 03, 04, 06, 09, 10, 11, 14, 15, 16, 17, 18, 21, 22, 24. c) List of variables that user can’t change during a run-cycle or while waiting for the Var12 Settle-Time to expire after a run-cycle: - Via the keypad: Vars 01, 02, 03, 04, 05, 06, 07, 08, 09, 10, 12, 13, 29, 38, 39. - Via serial interface: Vars 01, 02, 03, 04, 05, 06, 07, 08, 09, 10, 12, 13, 29, 38, 39, 53, 54, 55, 56, 57. Note: Vars 53, 54, 55, 56, and 57 can be changed, but changes do not take effect until next run-cycle. d) List of variables that user can’t change while the Cut-Signal alarm output operation is underway: - Via the keypad: Vars 38, 39. - Via serial interface: Vars 38, 39. Reference Length Variables (Vars 01, 02, 03): The Reference Variables convert encoder pulses into ‘User Units’. This allows the MicroLength to accept length Set Points, and to display in units meaningful to the operator. The MicroLength must be told how feedback encoder revolutions (and individual pulses) relate to production amounts and length Set Points, as defined in ‘User Units’. This conversion is done by programming the MicroLength with a ‘reference amount’ of product (Var01) defined in ‘User Units’. Then telling the MicroLength how many whole encoder revolutions (Var02) are needed to almost reach the ‘reference amount’ of product, plus how many extra encoder pulses (Var03) are needed to exactly reach the ‘reference amount’ of product. Mathematically this is seen as: The number of encoder pulses to reach ‘Var01 Reference Length’ = (Var02 x Var04) + (Var03). Or seen another way (i.e., Var28 System Resolution): The number of ‘User Units’ (or partial units) per ONE encoder pulse = Var01 / [(Var02 x Var04) + (Var03)]. (Note: Var04 Encoder PPR, is a system set-up variable, and is described in the System Set-up Variables section). If the exact gearing is known, then the reference variables can be programmed directly. If the exact gearing is not known, then Auto-Programming (Diagnostic Eight) can be used to find values for the reference variables. Var01 - Reference Length This variable is the ‘reference amount’ of product defined in ‘User Units’. The MicroLength uses this reference length to convert the feedback encoder pulses into units meaningful to the operator. Var01 can be entered with the decimal point in any position between X.XXXX and XXXXX. or without any decimal point. Var02 - Reference Length Whole Revolutions This variable is the number of complete revolutions the feedback encoder must turn to equal or almost reach the Var01’reference length’ of product. Var02 is limited to whole revolutions. Var03 - Reference Length Additional Pulses This variable is the number of extra pulses that must be added (fraction of a revolution) to the whole revolutions to obtain the ‘reference length’. Var03 is limited to whole pulses. Example 1: A system has a 1.5 ft circumference traction wheel connected to a 60 PPR encoder. The user wants the ‘reference length’ to be 1.5 ft (i.e., one rev of the traction wheel). The user must set-up the variables like this: Var01 = 1.5 (1.5 ft); Var02 = 1 (1 rev of wheel); Var03 = 0 (no extra pulses); Var04 = 60 (60 PPR). Example 2: A system has a 60 PPR encoder on the motor shaft, the motor shaft inputs to an 8.5 to 1 ratio gear-box, the gear-box output turns a 1 ft circumference nip roll. The user desires to have the length Set Points in units of ‘feet’. The user must set-up the variables like this: Var01 = 1 (1 ft); Var02 = 8 (8 whole revs); Var03 = 30 (30 extra pulses = ½ rev); Var04 = 60 ( 60 PPR). Page - 23 (Version 2.0) (00.08.22) PROGRAMMING SPECIFICS (cont.): System Set-up Variables (Vars 04, 05, 07, 08, 09, 10, 11, 18, 29): These variables tell the MicroLength the physical characteristics of the system: - Var04, feedback encoder pulses per revolution. - Var05, feedback encoder speed at maximum (99%) output. - Vars 07 and 08, how fast to change speeds. - Vars 09 and 10, how fast and slow to run during the cycle. - Var11, how fast to jog. - Var29, how wide is the system’s cutting saw. Also included here is Var18, Keypad Lockout feature (to prevent accidental reprogramming). Var04 - Feedback Pulses Per Revolution This variable is the number of pulses per revolution of the feedback encoder (PPR). Var04 is limited to whole pulses. Var05 - Maximum Feedback RPM This variable is the number of RPM the feedback encoder turns when the MicroLength’s Analog Output is outputting 100% maximum* voltage to the motor-drive. Failure to calibrate the Analog Output to the drive/motor, and not entering the resultant correct value into Var05, can cause poor run-cycle accuracy and Set Point repeatability. * Note: When the Analog Output is calibrated, the lower display actually can only run up to 99%, but for all practical purposes it can be called 100% maximum voltage. (See ‘MicroLength Set-up Procedure \Calibrating the Analog Output’ for using Diagnostic Nine to calibrate the Analog Output, and why this is so critical for accurate MicroLength operation). Var07 - Acceleration Time This variable is the time (in seconds) the MicroLength accelerates its Analog Output (and the motor/encoder) from 0 % to 100% output. Var07 must be entered in the XXXX.XX format, and has a range of 0000.10 to 0600.00 seconds. Note: The motor drive's acceleration time must be set to the fastest/shortest/quickest time possible. This allows the MicroLength’s acceleration time to be the dominant time, allowing the MicroLength complete control of acceleration. However, do not set the MicroLength’s acceleration time faster than the drive/motor can handle. Var08 - Deceleration Time This variable is the time (in seconds) the MicroLength decelerates its Analog Output (and the motor/encoder) from 100 % to 0% output. Var08 must be entered in the XXXX.XX format, and has a range of 0000.10 to 0600.00 seconds. Note: The motor drive's deceleration time must be set to the fastest/shortest/quickest time possible. This allows the MicroLength’s deceleration time to be the dominant time, allowing the MicroLength complete control of deceleration. However, do not set the MicroLength’s deceleration time faster than the drive/motor can handle. Var09 - High Speed Output Percent This variable is the maximum speed (as a % of Var05 Max RPM) the Microlength runs the encoder at during the run-cycle (i.e., the maximum voltage speed signal the MicroLength’s Analog Output sends the motor-drive during the run-cycle). Var09 can be from 1% to 100%, with the restriction being no less than Var10’s value. Var10 - Creep Speed Output Percent This variable is the speed (as a % of Var05 Max RPM) the Microlength runs the encoder at during the Creep Period of the run-cycle (i.e., the voltage speed signal the MicroLength’s Analog Output sends the motor-drive during the Creep Period of the run-cycle). Var10 can be from 1% to 100%, with the restriction being no more than Var09’s value. It is recommended to set Var10 between 5% and 20%. Note: During the Creep Period of the run-cycle, the actual encoder speed must be within 30% of Var10’s value, or poor control may occur. (This is apparent in drives having a very poor linear speed response across the entire band from 1% to 100%. Ex: At a 10% command voltage, a poor drive may run motor at 15% speed). Page - 24 (Version 2.0) (00.08.22) PROGRAMMING SPECIFICS \System Set-up Variables (cont.): Var11 - Jog Speed Output Percent This variable is the jog speed (as a % of Var05 Max RPM) the Microlength runs the encoder at during a jog command (i.e., the voltage speed signal the MicroLength’s Analog Output sends the motor-drive during a jog). Var11 can be from 1% to 100%. Var18 - Keypad Lockout This variable determines which Functions and Variables are locked out when the Keypad Lockout feature is enabled. After programming the MicroLength, setting and enabling the Keypad Lockout feature is recommended. Keypad Lockout is enabled by closing (via switch or hard-wire) the external switch input TB1-12 to Common. (See ‘WIRING AND I/O FUNCTION \External Switch Inputs’ for details). The Keypad Lockout options are shown in this table (entering a 1 Locks, and a 0 Unlocks the function, any combination of ‘lockouts’ can be selected): Selection code always * 000001 000010 000100 001000 010000 100000 Functions or Variables locked-out 2ND FUNC key and all Vars (except Vars 06, 09, 17, 24) * Var06 Batch Set Point Var09 High Speed Output Percent Var17 Display Selection Var24 Cycle Count SET POINT key RUN, STOP, JOG, and UP-ARROW keys * Note: Anytime the Keypad Lockout protection is enabled, the 2ND FUNC key and all Vars (except Vars 06, 09, 17, 24) are always ‘locked-out’ (the locked-out Vars may be viewed, but not changed). However, if Var18 is set to XX1111 (lockout all Vars including Vars 06, 09, 17, 24), then no Vars are allowed to be viewed (let alone changed). Var29 - Kerf Addition This variable is the distance (in ‘User Units’) the MicroLength is told to run a fixed extra distance beyond the Set Point length, to automatically account/compensate run-cycle length for material lost during cutting. (This allows the MicroLength to make up for a loss in length due to the cut of a saw blade without having to enter the extra length into the Set Point). If the application does not use a saw, or does not need to account for such length losses, then set Var29 to 0. Batch Set-up and Batch Monitor Variables (Vars 06, 23, 24) The MicroLength has the capability to count completed run-cycles (via Var24 Cycle Count), and to give an output signal (via Batch Complete alarm output) to indicate when a programmed count (i.e., Var06 Batch Set Point) has been reached. The MicroLength also counts the total batches run (via Var23 Batch Total). Var06 - Batch Set Point This variable is the number that sets how many run-cycles there are in a batch. When the Batch Set Point is reached, the Batch Complete alarm output activates (turns ON). (See ‘WIRING AND I/O FUNCTION \Status and Alarm Outputs’ for details on how/when the Batch Complete alarm output turns OFF). Var23 - Batch Total (Monitor only variable). Var23 keeps count of the number of batches completed. Var23 increments by one, each time the Var24 Cycle Count reaches the Var06 Batch set Point. Var23 resets to zero only when the Batch Reset external switch input is closed (see ‘WIRING AND I/O FUNCTION \External Switch Inputs’ for details). Var24 - Cycle Count (Semi-monitor only variable). Var24 keeps count of the number of run-cycles completed in the current batch. Var24 sets back to zero, when it (Var24) reaches the Batch Set Point (Var06). Var24 also resets to zero if the Batch Reset external switch input is closed. To allow for product removed from or added to the line, Var24 can be directly changed by the user. However, if the user enters a Var24 value exceeding the Var06 Batch Set Point value, then the Var23 Batch Total increments and the Batch Complete alarm output turns ON. Page - 25 (Version 2.0) (00.08.22) PROGRAMMING SPECIFICS (cont.): Display Variables (Vars 17, 16, and Diagnostic Zero): Var17 - Display Selection Var17 selects what data to show in the upper and lower displays. The upper display shows the numeric value of the data, the lower display shows what the data means. The default is ‘Length in the Cycle’, with “Feet” being the ‘Unit’ label in the lower display. The display options, and there selection codes are shown in this table: Selection code 0 1 2 3 4 Display option Length in the Cycle (in ‘User Units’) ‘User Units’ per Second (Rate) ‘User Units’ per Minute (Rate) Complete Batches (Counter) (i.e., same as Var23 tally) Complete Cycles in Current Batch (Counter) (i.e., same as Var24 tally) Var16 - User Label Var16 selects which ‘User Unit’ label to insert into the lower display (ex: “Feet”, “Ft”/sec’ “Ft”/min). The label options and there selection codes are shown in this table (the default is code 1, i.e., “Feet”): Selection code Unit Label Selection code Unit Label Selection code Unit Label 0 Inches 6 Revs 12 Turns 1 Feet 7 Ounces 13 Pints 2 Yards 8 Gallons 14 Quarts 3 MM 9 mL 15 Cubic In 4 CM 10 Liters 16 Cubic cm 5 Meters 11 lbs 17 (custom) * * Note: Code ‘17’, selects the users own custom programmed label. (See Diagnostic Zero below for details). General Note: The Var16 User Label selection is evident only for Var17 selection codes 0, 1, or 2; since these three Var17 display selections are the only ones that deal with ‘User Units’. Diagnostic Zero – Custom User Unit Label Programming: If the choices presented in Var16 do not provide the Unit Label needed, then a custom ‘User Unit’ label can be created using Diagnostic Zero. The following characters can be used in a custom ‘User Unit’ label: A B C D E F G H I J K L M N O P Q R S T U V W X Y Z l 2 3 4 5 6 7 8 9 / * + − _ and "blank". Follow these steps (in order) to use Diagnostic Zero to create a custom ‘User Unit’ label: a) Access Diagnostic Zero by pressing the 2ND FUNC key and then the ‘0’ key: - Any previous custom ‘User Unit’ label programming is immediately erased! - The upper display shows “000000”. - The lower display shows eight underscore characters "_ _ _ _ _ _ _ _ ". - The left-most character in the lower display is the character to be changed first. b) Press the UP-ARROW key: - This changes the left-most underscore to the letter "A." - Pressing the UP-ARROW key again changes the "A" to "B", and so on. - Pressing the DOWN-ARROW key changes the "A" to a blank space. - The UP-ARROW key scrolls forward through the character list; the DOWN-ARROW key scrolls backward through the character list. c) When the desired character for the position is displayed, press the ENTER key. - This locks the character into position, and enables the next position in the lower display to be programmed. d) Repeat steps (b) and (c) until all eight characters in the lower display have been custom programmed. - Pressing the ENTER key after the right-most character in the lower display has been programmed, saves the custom programming, exits from Diagnostic Zero, and brings the MicroLength back to "READY" mode. Note: If your custom ‘User Unit’ label has less than eight characters in it, or if you want to end custom programming before entering all characters, then press the 2ND FUNC key at any time. This saves custom label programming, exits from Diagnostic Zero and returns the MicroLength to the "READY" mode. Page - 26 (Version 2.0) (00.08.22) PROGRAMMING SPECIFICS \ Display Variables \Diagnostic Zero (cont.): e) Once back in the “READY” mode, the last two steps are to set Var16’s code to 17 (to select the ‘custom User Unit’ label), and to set Var17’s code to 0 (to select ‘Length in the Cycle’). Note: Var17 Display Selection code must be 0 if you want to see the Var16 ‘custom User Unit’ label inserted into the lower display. Otherwise when Var16 is set to code 17, if Var17 code is 1 or 2, then the lower display shows a generic “Unit/SEC” or “Unit/MIN”. (Var17 codes 3 or 4 don’t deal with ‘Units’, and won’t show the Var16 Unit label in any shape or form). Note: The pre-programmed labels in Var16 are still available by setting Var16 to the desired selection code. System Performance Monitor Variables (Vars 25 - 28, 30 - 35): These ‘monitor only’ variables provide information on system performance and the status of internal counters and timers. These variables cannot be user programmed, since they are ‘monitor only’. Var25 - Feedback Frequency (Monitor only variable). Var25 holds the real-time value of feedback encoder frequency. Var25 can be viewed during a run-cycle. Var25 can be used to determine if the anticipated RPM is being reached during the Maximum speed and Creep speed portions of the run-cycle. Var26 - Actual Creep Speed Time (Monitor only variable). Var26 shows how long the feedback encoder RPM was at the Var10 Creep Speed level in the previous cycle. Var26 can be compared to the Var13 Ideal Creep Time, to ensure proper operation. Var26 should read be between 0.5 and 1.5 times the Var13 Ideal Creep Time. Var27 - Position Error (Monitor only variable). Var27 shows the number of pulses the MicroLength was ‘off’ (in error) of the length Set Point in the previous completed run-cycle. Var28 - Resolution (Monitor only variable). Var28 shows the resolution of the system, as defined by how many of your ‘User Units’ (or fractional parts of your ‘User Unit’) are represented by 1 feedback encoder pulse. Var28 tells you how accurate the end result of the length profile can be for your system. It is not recommended to use a length Set Point set to a value containing finer accuracy than the feedback encoder and system are equipped to resolve. Mathematically, Var28 is seen as: The number of ‘User Units’ (or partial units) per 1 encoder pulse = Var01 / [(Var02 x Var04) + (Var03)]. Var30 - Stop Correction Pulses (Monitor only variable). Var30 is the correction-factor (in pulses) used by the MicroLength to coast the encoder to a stop. The Microlength calculates the necessary value of Var30 while ‘learning’ the system’s inertial behavior. Var30 comes into play after the MicroLength cuts-off its Analog Output (at the end of the creep speed portion of the run-cycle) and the encoder coasts/regens to a stop. Var30 is first calculated during the ‘LEARNING’ process, and later tweaked by the Microlength if need be. Var31 - Decel Correction Pulses (Monitor only variable). Var31 is the correction-factor (in pulses) used by the MicroLength to tweak the decel ramp. The Microlength calculates the necessary value of Var31 while ‘learning’ the system’s inertial behavior. The MicroLength uses Var31 to adjust (sooner or later than ideal) the point at which to begin the decel ramp from high speed and head towards creep speed. Var31 is first calculated during the ‘LEARNING’ process, and later tweaked by the Microlength if need be. Var32 - Output Creep Time (Monitor only variable). Var32 gives the amount of time (in seconds) the Analog Output was at the creep output percent in the previous completed run-cycle. Page - 27 (Version 2.0) (00.08.22) PROGRAMMING SPECIFICS \System Performance Monitor Variables (cont.): Var33 - Last Cycle High Output % (Monitor only variable). Var33 gives the highest percent of Analog Output achieved in the previous completed run-cycle. Var34 - Last Cycle High RPM (Monitor only variable). Var34 gives the highest RPM achieved in the previous completed run-cycle. Var35 – Minimum Set Point Length (Monitor only variable). Var35 gives (in ‘User Units’) the shortest run-cycle theoretically possible that still allows the encoder to reach Var09 High Speed for at least 200 ms. The MicroLength calculates the ‘MinSetPt’ length corresponding to the Vars 01, 02, 03, 04, 05, 07, 08, 09, 10, and 13. It is critical a regular run-cycle reaches Var09 High Speed, since this is the speed from which the Microlength ‘LEARNED’ the system’s inertial stopping behavior. (If Var09 High Speed is not reached during a regular run-cycle, then the inertial behavior would not be as expected, and the run-cycle accuracy would diminish). Var35 is displayed using the same format and decimal point location as the active length Set Point. If Var35’s value is too large to display using the same format and decimal point location as the active Set Point, then the Var35 overflow value displays as ”- - - - - - “. Note: In the event of Var35 ”- - - - - - “ overflow, the user can try changing the format and decimal point location of the active length Set Point to one of lower resolution. Example: If the format of the active Set Point is XXX.XXX, then try changing to XXXX.XX Status and Alarm Output Variables (Vars 21, 22, 38, 39): Var21 - Deviation Alarm This variable is the number of pulses ± from the Set Point at which the Deviation Alarm output activates (turns ON). Var22 - Drive Enable This variable determines the Drive Enable Alarm Output’s reaction by the MicroLength to stop the drive/motor/encoder. The choices are the following: 1 - Drive Enable is deactivated when the Analog Output voltage is zero. 2 - Drive Enable is deactivated when the Analog Output voltage and feedback encoder frequency are both zero. 3 - Drive Enable is deactivated simultaneously with a Stop Command. Var38 - Cut-Delay This variable is the desired time-delay to wait before turning ON the Cut-Signal output, at the end of a run-cycle (after the Var12 Settle-Time has ended). Var38 is limited to the XXXX.XX format, has a range of 0000.00 to 0099.99 seconds, and a default of 0001.00 sec. Var39 - Cut-Time This variable is the desired time to hold ON the Cut-Signal output (at the end of a run-cycle after the Cut-Signal output turns ON). After Var39 time expires, the Cut-Signal output turns OFF. Var39 is limited to the XXXX.XX format, has a range of 0000.00 to 0099.99 seconds, and a default of 0001.00 sec. Disable the Cut-Signal output by setting Var39 to 0000.00 sec. Page - 28 (Version 2.0) (00.08.22) PROGRAMMING SPECIFICS (cont.): Fine-Tuning Variables (Vars 12, 13, 14, 15): Fine-Tuning the MicroLength is composed of tweaking the tuning Variables 12-15. Var12 - Settle Time Var12 is the time to wait after the Set Point is reached, to allow the system to ‘settle’, before activating the ‘At Position’ alarm output. Var12 is also the time the MicroLength’s correction-algorithm waits after a run-cycle, before it checks the error between the desired Set Point and the actual length reached, and calculates corrections for the next run-cycle. (The MicroLength does not take into consideration any movement that happens after the Var12 Settle-Time has expired. Therefore Var12 must be set long enough so that all movement has stopped before the correctionalgorithm does its check). Var12 is limited to the XXXX.XX format, and has a range of 0000.10 to 0600.00 seconds. Note: If Var12 is too small, resulting in the motor/encoder not coming to a complete rest before the MicroLength’s correction-algorithm checks the error and makes calculations for the next run-cycle, then poor run-cycle accuracy and repeatability may be experienced. Var13 - Ideal Creep Time Var13 is the amount of time the MicroLength spends at slow speed ‘creeping-up’ on the desired Set Point length. Good run-cycle accuracy and repeatability is accomplished by ensuring the motor is under complete control as the Set Point length is approached. The MicroLength uses Creep Speed (Var10) and Creep Time (Var13) to ensure complete motor/encoder control as the Set Point length is approached. Var13 is limited to the XXXX.XX format, and has a range of 0000.20 to 0600.00 seconds. See ‘Introduction \Summary of Operations’ and ‘Introduction \Details of Operations \Open-loop Control Issues’ for more details on MicroLength control. Note: If the system's motor/drive/encoder tracks the MicroLength's Analog Output well, then less Var13 Creep Time is necessary. Var14 - Integral Start Var14 tells the MicroLength when to stop using large correction (or proportional correction), and begin the small step or one pulse correction (integral). Integral Start is entered in pulses. As long as the length of travel is within this plus or minus window, the MicroLength will change the stopping ramp point by only 1 feedback pulse. By setting Integral Correction to zero, it can be used to set-up a dead band in a system with more accuracy in feedback pulses than required for the final product. Var14 is limited to whole pulses. Var15 - Integral Correction Var15 value tells the MicroLength how many consecutive times the cycle length must be either too-long or too-short before making an integral (or one pulse) correction. The object of this function is to correct only if the system can repeatedly duplicate a stopping point. - Setting Var15 = 0; turns integral correction off and creates a dead band in which the MicroLength will not correct the stopping point. - Setting Var15 = 1; tells the MicroLength to correct for every error within the integral start window. - Setting Var15 = 2; tells the MicroLength that the length must consecutively run long twice or short twice before making a one pulse correction, etc. Var15 is limited to whole numbers. Page - 29 (Version 2.0) (00.08.22) SECTION VI DIAGNOSTICS (2nd Function Key) There are six ‘2nd Functions’ that are true diagnostic tests, and which are used to test the health of the MicroLength itself. (Diagnostics 1, 2, 3, 4, 5, and 6). There are four ‘2nd Functions’ that are not truly diagnostic tests, but which are used to assist in programming and also in calibrating the Isolated Command Output (a.k.a. Analog Output) to the drive. (Diagnostics 0, 7, 8, and 9). To access any of the ten ‘2nd Functions’ (Diagnostics) follow these steps: - press the 2ND FUNC key. - press the number key that corresponds to the desired ‘2nd Function’ or Diagnostic test. (Ex: Diagnostic 1 is accessed by pressing the 2ND FUNC key followed by the ‘1’ key). - perform the desired ‘2nd Function’ or Diagnostic test. - press the 2ND FUNC key again to exit the ‘2nd Function’ or Diagnostic test. Descriptions of Diagnostics or 2nd Functions: Diag. 0 - Custom User Unit Label Programming – THIS IS NOT A TEST. ‘2nd Function’ Diagnostic Zero is used in ‘custom programming’. (See Programming Specifics, Display Variables – Var16, and Diagnostic Zero). Diag. 1 - Keypad Test – This diagnostic is used to test the keypad. The numeric-only display (the upper display) shows: - “111111”, “222222”, “333333”, etc., when the numeric keys are pressed. - “000000” when non-numeric keys are pressed. The alpha-numeric display (the lower display) shows the name of the key: - "one", "two", “three”, etc, is shown when the numeric keys are pressed. - "Variable", "Up Arrow", “Stop”, etc, is shown when the non-numeric keys are pressed. Diag. 2 - Display Test – This diagnostic is used to test all the LED segments in the upper and lower displays, and all the LED indicator lights in the lower-left portion of the front-panel. During this test: - the upper display scrolls through all of the numbers (111111, 222222, 333333, etc.) and scrolls the decimal point through each possible location. - the lower display scrolls through all of the numbers (11111111, 22222222, 33333333, etc.). - the 6 discrete LED indicator lights in the lower-left of the front-panel light up one at a time. Diag. 3 - Input Switch Test – This diagnostic is used to test each of the external switch inputs. Toggle each external switch input, and observe the appropriate display, to test if it is properly wired and functional. The E-Stop, Run, Jog, and Stop switch inputs are represented by a 0 or a 1 on the upper display: - Left to right, the last four digits of the upper display (XX0000) correspond to these four switch inputs as follows: E-Stop; Run; Jog; Stop. - When the Run or Jog input is Open the corresponding digit shows a 0, when Closed it shows a 1. (Note: The Run and Jog are activated and held when Closed, thus the display shows 1 when activated). - When the E-Stop or Stop input is Open the corresponding digit shows a 1, when Closed it shows a 0. (Note: The E-Stop and Stop are activated and held when Open, thus the display shows 1 when activated). All the other switch inputs (Local/Remote, Keypad Lockout, Forward/Reverse, etc.) are represented by a 0 or a 1 on the lower display: - Left to right, the eight digits of the lower display (00000000) correspond to these eight switch inputs as follows: Run at High Speed; Batch Reset; Forward/Reverse; Keypad Lockout; Set Point 1(3)/2(4); Set Points 3 & 4 Enabled ; TB1- 8 (reserved) ; End Cycle. - When the digit corresponding to that input shows a 0 the input is Open, when it shows a 1 it is Closed. Page - 30 (Version 2.0) (00.08.22) DIAGNOSTICS (2nd Function Key) (cont.): Diag. 4 - Memory Test – This diagnostic is used to test the micro-processor’s internal memory locations. The lower display shows "TEST ROM" for a few seconds, then it displays "ROM OK" or "FAIL". Diag. 5 - Output Alarm Test – This diagnostic is used to test the Status and Alarm outputs: - When this test is first entered, the lower display shows "OUTPUTS" until a key 1 through 6 is pressed. - When a numeric key 1 through 6 is pressed, the corresponding Output Alarm circuit activates (turns ON), and the lower display shows the name of the output being tested. The upper display shows “LO” to indicate that the Output Alarm is in the ON state (i.e., pulled to the logic low level). - After an output is tested, press the STOP key to turn the output OFF. The upper display shows “HI” (until the STOP key is released) to indicate that the Output Alarm is in the OFF state (i.e., returned to the logic high level). - To exit this Diagnostic, first turn any active output OFF, then press the 2ND FUNC key. The numeric keys 1 through 6 correspond to the Output Alarms as follows: 1 = Cut-Signal, 2 = At Position, 3 = Batch Complete 4 = Low Speed, 5 = Deviation Alarm, 6 = Drive Enable Diag. 6 - Communications Test – This diagnostic is used to test the RS422 serial communications hardware. To perform this test, first place jumper wires between the Send and Receive lines (RXD- to TXD-, and RXD+ to TXD+). Then press the 2ND FUNC key, followed by the ‘6’ key, to access Diagnostic Six: - the MicroLength automatically tests its communication circuitry to make sure it is functioning. - during the test, the lower display shows “COM TEST”. - if the communication circuitry tests out good, then the lower display shows "PASS", and the upper display shows the node address. - if the communication circuitry tests out bad, then the lower display shows "FAIL". Diag. 7 - Reset to Factory Programming – THIS IS NOT A TEST. WARNING!! Before accessing Diagnostic Seven, make sure you have recorded any user variable values you want to save (if different from the factory-default values). Diagnostic Seven will ERASE your user values and replace them with factory-default values. After performing Diagnostic Seven, you can then re-load your specific user values if desired. (See ‘Appendix A’ for a list of factory-default values, and for a handy place to record your specific user variable values). Pressing the 2ND FUNC key, followed by the ‘7’ key, accesses Diagnostic Seven: - Diagnostic Seven resets all the user variable programming in memory to the factory-default values. - Diagnostic Seven also resets the system’s ‘Learned Behavior’ correction-factors (Vars 30 and 31). This causes the MicroLength to automatically go through the ‘learning’ process during the next few run-cycles. - During the ‘reset-to-default’ process, the lower display shows the following sequence of messages: “FACT RST”, “” for 0.25 seconds, then “RESET OK”. Diag. 8 - Auto Programming – THIS IS NOT A TEST. ‘2nd Function’ Diagnostic Eight is used to automatically acquire values for user Vars 01, 02 and 03. (See ‘MicroLength Set-up Procedure \Prog. Reference Length Vars’ for details on Diagnostic Eight). Diag. 9 - Digital Speed Pot – THIS IS NOT A TEST. ‘2nd Function’ Diagnostic Nine is initially used to calibrate the Analog Output. However, after the Analog Output has been calibrated, Diagnostic Nine can later be used as a test to verify the Analog Output’s performance. See ‘MicroLength Set-up Procedure \Calibrating the Analog Output’ for using Diagnostic Nine to calibrate the Analog Output, and why this is so critical for accurate MicroLength operation. Page - 31 (Version 2.0) (00.08.22) SECTION VII SERIAL COMMUNICATIONS (Via RS422) The Remote Serial Interface: The RS422 serial interface allows the MicroLength to be remotely controlled via serial communications. For remote control applications, the MicroLength can be set-up to only accept control via the RS422 link, or to allow some operator control as programmed with the ‘External Switch and Keypad Enable In Remote Mode’ variable (Var47). When in remote mode, all new Set Points and programming must come over the RS422 link. To control through the RS422 Serial Interface, the Local/Remote external switch input (TB1-10) must be closed to common (TB1-11). Note: It is recommended that an optically isolated RS422 link be used between your computer and the MicroLength. Electrical noise will corrupt data on the computer, causing it to send bad data, interpret data incorrectly, or lock up computer functions. Prolonged exposure of your computer to electrical noise will destroy your computer! Correct RS422 Connections: MicroLength #1 Host Device TB2-5 TXD + RXD + TB2-6 TXD - RXD - TB2-7 RXD + TXD + TB2-8 RXD - TXD - TB2-9 COMMON COMMON TB2-5 TXD + TB2-6 TXD TB2-7 RXD + TB2-8 RXD TB2-9 COMMON MicroLength #'n' Page - 32 (Version 2.0) (00.08.22) SERIAL COMMUNICATIONS (cont.): Communication Protocol: The communication protocol used by the RS422 serial interface is a 15 character command format. Each character has 1 start bit, 8 data bits, 1 stop bit and no parity. The host sends messages in this format and the addressed MicroLength responds in the identical format. The time from the end of the host message to the start of the MicroLength message can vary from 10 to 30 milliseconds, depending on the type of the host message. The following diagram shows the command format 15 character string: Char # 0 1 2 3 stx Device Type Node Address (10’s) Node Address (1’s) 4 5 6 Message Var # (10’s) Type, or Error Flag Var # (1’s), or Command / Error type 7 8 Data Data 100,000’s 10,000’s 9 10 Data Data 1,000’s 100’ s 11 12 13 14 Data 10’s Data 1’s Decimal Point Location etx Command format character descriptions: Char # Description ASCII Value Typical Keyboard 0 Stx (start of transmission) 02 hex Ctrl-B 1 Device type 31 hex 1 2 Node Address (10’s digit) 30-39 hex 0-9 3 Node Address (1’s digit) 30-39 hex 0-9 4 Message Type / Error Flag 30-39 hex 0-9 5 Variable # (10’s digit) 30-39 hex 0-9 6 Variable # (1’s digit), Command Type / Error Type 30-39 hex 0-9 7 Data (100,000‘ s digit) 30-39 hex, 2D hex ** 0-9, “-“ 8 Data (10,000‘ s digit) 30-39 hex 0-9 9 Data (1,000‘ s digit) 30-39 hex 0-9 10 Data (100‘ s digit) 30-39 hex 0-9 11 Data (10‘ s digit) 30-39 hex 0-9 12 Data (1‘ s digit) 30-39 hex 0-9 13 Decimal Point Location 30-36 hex 0-6 14 Etx (end of transmission) 03 hex Ctrl-C ** The ASCII character "-" may be returned by the MicroLength, but must not be sent to the MicroLength. Character 0: stx Used to indicate the start of the 15 character string transmission. The MicroLength uses this character to open a new segment in the receive buffer. Character 1: Device Type Used to indicate device type. This is always a 1 for the MicroLength. Character 2 and 3: Node Address (10's and 1's digits) Used to select an individual MicroLength on the communications link. These two characters correspond to the Node Address (Var 19) of the MicroLength. (Char # 2 is the 10's location, char # 3 is the 1's location). - Note: The node address of 00 is reserved for selecting the GLOBAL address. All MicroLengths are affected by a GLOBAL message but only address 01 will return a response to the host. Page - 33 (Version 2.0) (00.08.22) SERIAL COMMUNICATIONS \Communication Protocol \Command format character descriptions (cont.): Character 4: Message Type / Error Flag Used to select which ‘message’ to send to the MicroLength. The MicroLength then echoes the same message back to the host using this same character location. If the host device message contained an error, then the MicroLength does not echo, but rather sends an error flag (message ‘3’) back to the host device: Char # 4 value Message 0 COMMAND message (sent from host to MicroLength) 1 READ variable message (sent from host to MicroLength) 2 WRITE variable message (sent from host to MicroLength) 3 ERROR flag message (sent from MicroLength to host) Note: See ‘Serial Communications \Using the Serial Protocol’ for details on using these messages. Character 5 and 6: Variable Number (10's and 1's digits) - When sending either the READ or WRITE message, chars #5 and # 6 are used to select which MicroLength variable to access. - When sending the COMMAND message, character # 6 is used to select which type of command to send to the MicroLength (start, stop, etc.). (See ‘Serial Communications \Using the Serial Protocol \Message Type = 0 \Command Types’ for details on command ‘types’). - When the MicroLength sends the ERROR flag message to the host device, the error type is specified in character # 6. (See ‘Serial Communications \Using the Serial Protocol \Message Type = 3’ for details on error ‘types’). Characters 7-12: Data Field Used to hold the data being passed between the host and the MicroLength: Char # 7 8 9 10 11 12 Purpose Holds the 100,000’s digit value Holds the 10,000’s digit value Holds the 1,000’s digit value Holds the 100’s digit value Holds the 10’s digit value Holds the 1’s digit value Character 13: Decimal Point Location Used to select the location of the decimal point in the data field: Selection code 0 1 2 3 4 5 6 Decimal Point Location X.XXXXX XX.XXXX XXX.XXX XXXX.XX XXXXX.X XXXXXX. XXXXXX (no decimal point) Character 14: etx (End of Transmission) Used to indicate the end of the 15 character string transmission. Page - 34 (Version 2.0) (00.08.22) SERIAL COMMUNICATIONS (cont.): Using the Serial Protocol This section discusses how to use the RS422 serial link to send/use the GLOBAL message and Message Types 0 through 3. (See ‘Serial Communications \Communication Protocol \Command format character descriptions \Characters 2 and 3’ for details on how to address for a GLOBAL message). (See ‘Serial Communications \Communication Protocol \Command format character descriptions \Character 4’ for details on Message Types 0 to 3). GLOBAL Message 1) Enter start-of-transmission ‘Stx’ (Ctrl-B) into char # 0. 2) Enter a 1 into char # 1. 3) Enter a 0 into both chars #2 and # 3 (GLOBAL messages are given by selecting node address 00). 4) Enter the desired message (0 = COMMAND, 2 = WRITE) into char # 4. (Note: The READ message, type = 1, is not allowed for Global addressing. A global ‘read’ will prompt node 01 to respond with an error message). 5) If you entered 0 (COMMAND message) into char # 4 for a ‘global command’, then follow steps (5a) and (5b): a) Enter 0 into char # 5. b) Enter the desired command type into char # 6. (See ‘Serial Communications \Using the Serial Protocol \Message Type = 0 \Command Types’, for details on the six different command ‘types’): - If you entered 4 (Change Set Point Value command) into char # 6, then enter the new length Set Point value and decimal point location into chars # 7 through # 13. - If you entered any other command type (0, 1, 2, 3, or 5) into char # 6, then enter 0’s into chars # 7 to # 13. 6) If you entered 2 (WRITE message) into char # 4 for a ‘global write’, then follow steps (6a) and (6b): a) Enter the desired variable number to access into chars # 5 and # 6. b) Enter the desired data and decimal code into chars # 7 to # 13. 7) Enter end-of-transmission ‘Etx’ (Ctrl-C) into char # 14. Note: Only node 01 returns a response to a GLOBAL message, but all MicroLengths act on the message. Message Type = 0 (COMMAND Message): 1) Enter start-of-transmission ‘Stx’ (Ctrl-B) into char # 0. 2) Enter a 1 into char # 1. 3) Enter the desired node address using chars # 2 and # 3. 4) Enter a 0 (COMMAND message) into char # 4. 5) Enter a 0 into char # 5. 6) Enter the desired command type (0 through 5) into char # 6. (See table on next page for details on the six different command ‘types’ which can be sent to the MicroLength): - If you entered 4 (Change Set Point Value command) into char # 6, then enter the new length Set Point value and decimal point location into chars # 7 through # 13. - If you entered any other command type (0, 1, 2, 3, or 5) into char # 6, then enter 0’s into chars # 7 to # 13. 7) Enter end-of-transmission ‘Etx’ (Ctrl-C) into char # 14. Example: Interrupt-Stop all MicroLengths at same time, by using the GLOBAL address and the Stop COMMAND. (Set chars # 2 and # 3 both to 0, to select the GLOBAL address 00. Set char # 4 to 0 to select the COMMAND message. Set char # 6 to 1 to select the STOP command). message sent - stx1000010000000etx message returned - stx1010010000000etx Page - 35 (Version 2.0) (00.08.22) SERIAL COMMUNICATIONS \Using the Serial Protocol \Message Type = 0 (COMMAND Message) (cont.): Command ‘Types’ (0 through 5): When char # 4 is set to 0 (the COMMAND message), then char # 6 is used to select the Command ‘type’. The six Command ‘types’ are described in this table: Selection code (char # 6) 0 1 2 3 4 5 Command ‘type’ description Start: - Starts (or resumes) the specified MicroLength run-cycle. - Command type 0 is ignored if the front or back panel ‘stop’ has been enabled (via the External Switch/Keypad Enable In Remote Mode Var47) and a ‘stop’ is held. Stop: - Interrupt-stops the specified MicroLength during a run-cycle. E-Stop: - E-stops the specified MicroLength. Set to Factory Defaults: - Sets all variables of the specified MicroLength to the factory default values (except for Var19 Node Address, Var20 Baud Rate, and Var47 External Switch/Keypad Enable In Remote Mode). - During the ‘reset-to-default’ process, the MicroLength’s lower display shows the following sequence of messages: “FACT RST”, “”, “RESET OK”, and “READY”. - Command type 3 is ignored during a run-cycle, and during the Var12 Settle Time after a run-cycle. - Command type 3 also resets the systems ‘Learned Behavior’ correction-factors (Vars 30 and 31). This causes the MicroLength to automatically go through the ‘learning’ process during the next few run-cycles. Change Set Point Value: - Changes the selected active Set Point to the new value sent (the new Set Point value and decimal point location are sent via chars # 7 through # 13). - Command type 4 changes only the active Set Point. To change any other Set Points (non-active Set Points), use the WRITE message. - If command type 4 is used to change the active Set Point during a run-cycle, or during the Var12 Settle Time after a run-cycle, then the new value does not take effect until the next run-cycle. End cycle: - Command type 5 operates like the End Cycle input. Sending command type 5 while at an interrupt-stop, aborts the present run-cycle. Page - 36 (Version 2.0) (00.08.22) SERIAL COMMUNICATIONS \Using the Serial Protocol (cont.): Message Type = 1 (READ Variable Message): 1) Enter start-of-transmission ‘Stx’ (Ctrl-B) into char # 0. 2) Enter a 1 into char # 1. 3) Enter the desired node address using chars # 2 and # 3. 4) Enter a 1 (READ message) into char # 4. (Note: Global ‘reads’ not allowed). 5) Enter the desired variable number to access into chars # 5 and # 6. 6) Enter 0’s into chars # 7 to # 13. 7) Enter end-of-transmission ‘Etx’ (Ctrl-C) into char # 14. The MicroLength will mirror the message string with the data and decimal field filled (chars # 7 to # 13). Example: read node 01, variable 01, when variable 01 = 1800 message sent - stx1011010000000etx message returned - stx1011010018006etx Message Type = 2 (WRITE Variable Message): 1) Enter start-of-transmission ‘Stx’ (Ctrl-B) into char # 0. 2) Enter a 1 into char # 1. 3) Enter the desired node address using chars # 2 and # 3. 4) Enter a 2 (WRITE message) into char # 4. 5) Enter the desired variable number to access into chars # 5 and # 6. 6) Enter the desired data and decimal code into chars # 7 to # 13. 7) Enter end-of-transmission ‘Etx’ (Ctrl-C) into char # 14. The MicroLength will mirror the message string. Example: write node 27, variable 07, the data 0015.00 message sent - stx1272070015003etx message returned - stx1272070015003etx Note: If Var 01, 02, 03, 04, 05, 07, 08, 09, 10 or 13 is changed (via the WRITE message), then the MicroLength automatically resets the system’s ‘Learned Behavior’ correction-factors (Vars 30 and 31). The MicroLength then goes through the ‘learning’ process during the next few run-cycles and acquires new behavior correctionfactors (Vars 30 and 31) that correspond to the new Var 01, 02, 03, 04, 05, 07, 08, 09, 10 or 13. Message Type = 3 (ERROR Flag Message): If the MicroLength detects an error in the host message, it sends the ERROR flag (message ‘3’) in the char #4 position. The MicroLength then specifies the error type using the char #6 position. The possible error ‘types’ are listed in this table: Error Code (char # 6) 1 2 3 4 5 Error ‘type’ description Parity error (standard definition) Data error (data outside of range 1 through 9) Global READ error (can’t use address 00 during READ) Etx error (etx came early, late, or not at all) General error (due to any of the following conditions): - Message type out of range 0 through 2. - Command type out of range 0 through 5. - Variable value out of range. - WRITE message sent to a protected variable during a run-cycle. - COMMAND or WRITE messages sent while in local mode. - Zero sent as a length Set Point. Page - 37 (Version 2.0) (00.08.22) SERIAL COMMUNICATIONS (cont.): Serial Communications Variables: Serial Communication Set-up Variables: Vars 19, 20 and 47 must be set-up from the MicroLength keypad before switching the MicroLength over to remote mode. (Vars 19, 20 and 47 can be viewed, but not changed via the serial communications link). Var19 - Node Address Enter the desired address (between 01 and 99). This address will be used in the command format to talk to that MicroLength only. When using the GLOBAL address (address 00) the MicroLength with node address 01 will be the only control to answer the host computer, but all MicroLengths will act upon the GLOBAL message. Never duplicate an address on the same communications port. Var20 - Baud Rate Enter the selection code corresponding to the desired operating baud rate: Selection code Baud rate 1 300 2 1200 3 2400 4 4800 5 9600 6 19200 Var47 – External Switch and Keypad Enable In Remote Mode This variable allows certain functions (i.e., external switch inputs or keypad buttons) to be active during remote mode. Entering a 1 enables the functions. Entering a 0 disables the functions. The E-STOP external switch input is active in any mode of operation and cannot be disabled. Any combination of functions can be selected. Enter the desired selection code: Selection code 000001 000010 000100 001000 These external switch inputs: These external switch inputs: These external switch inputs: These Keypad buttons **: Functions enabled Run, Stop, Jog Fwd/Rev, Batch Reset, Run @ Hi-Speed, End Cycle Set Point selects 1, 2, 3, 4 Run, Stop, Jog, End Cycle (UP-ARROW) ** Note: These keypad buttons cannot be enabled in remote mode if locked-out via the Var18 Keypad Lockout feature. Serial Communication Troubleshoot Variable: Var48 - Buffer Error (Monitor only variable). This variable is used to help diagnose communication errors. The most recent error is kept in this variable. This variable can be viewed via the MicroLength keypad or the serial communications link, but cannot be changed via either method. The buffer error codes are explained in this table: Error code 0 1 2 Status No errors MicroLength received characters outside of the expected protocol format MicroLength received transmissions faster than it can process information and respond Page - 38 (Version 2.0) (00.08.22) SERIAL COMMUNICATIONS (cont.): Serial Communication Control and Monitor Variables: These variables are accessible only via the serial communications link (they are not accessible via the MicroLength keypad). (See ‘Communication Protocol’ for details of the serial communication 15 character command format). Var49 - New Set Point (Monitor only variable). Used as an internal new Set Point holding location when using command type 4. Var50 - Serial Status (Monitor only variable). Var50 contains information on the present state of the MicroLength. Data is returned in chars # 7, # 8, and # 9 of the serial 15 character format, as shown in these tables: Char # 7 value 0 1 2 3 4 5 6 7 8 Operation status E-Stop Entry error ** Interrupt-Stop Running at High Speed Running Ready mode (not used) No feedback Digital Speed Pot or Auto-Programming modes (Diagnostic 8 or 9) Char # 8 value 0 1 Operation status Local mode Remote mode Char # 9 value 1 2 3 4 Operation status Set Point 1 active Set Point 2 active Set Point 3 active Set Point 4 active ** Char # 7 = 1, Entry Error - This occurs if the values entered into Vars 01, 02, and 03 and the Set Point total more than 2,147,500,000 pulses. This is the maximum total pulse-count the MicroLength can accommodate. Var51 - Clear Batch Counter Var51 is used to remotely reset to 0 the Var23 Batch Total and the Var24 Cycle Counter, and turn OFF the Batch Complete alarm output (similar to the Batch Reset external switch input, TB1-15). This done by sending the serial 15 character format with the WRITE message and with data as follows: chars # 7 through # 11 as all 0’s, char # 12 as a 1, and char # 13 as a 6. Var53 - Forward or Reverse Var53 is used to remotely select the Analog Output polarity (similar to the Fwd/Rev external switch input, TB1-13). This done by sending the serial 15 character format with the WRITE message and with data as follows: chars # 7 through # 11 as all 0’s, char # 13 as a 6, and char # 12 as a 0 for Forward or char # 12 as a 1 for Reverse. (Note: The ‘Fwd/Rev’ function is not intended for using the MicroLength as a bi-directional length controller, but rather only for jogging or creeping in the opposite direction if need be). Var54 – Set Point Length 1 in User Units. Var55 – Set Point Length 2 in User Units. Var56 – Set Point Length 3 in User Units. Var57 – Set Point Length 4 in User Units. Vars 54 through 57 are used to remotely change any of the four length Set Points. This done by sending the serial 15 character format with the WRITE message and with the new Set Point value and decimal point location in data chars # 7 thru # 13. (See ‘Serial Communications \Using the Serial Protocol \Message Type = 0 \Command Type 4’ for related information about changing the active Set Point). Var62 - Display (Monitor only variable). Var62 shows the present data displayed in the upper display of the MicroLength. Refer to Display Selection (Var17) for details on what is displayed. Data is returned in chars # 7 through # 13 of the serial 15 character format. Var63 - Alarm Status (Monitor only variable). Var63 shows which alarm outputs are ON. If an alarm output is ON, then the corresponding data character will be a 1. Data is returned in chars # 7 through # 12 of the serial 15 character format. The ‘character-to-alarm output’ association is shown in this table: Char # 7 8 9 Alarm Output Cut-Signal At Position Batch Complete Char # 10 11 12 Page - 39 Alarm Output Low Speed Deviation Alarm Drive Enable (Version 2.0) (00.08.22) SERIAL COMMUNICATIONS (cont.): Serial Communications Appendix (troubleshooting): Problems: 1) The unit does not act on or respond to messages sent: Possible causes/remedies: - Check Baud Rate and Address. - Check wiring. - Check Buffer Error (Variable 48) for communication errors. - All 15 characters not sent. - Unit is not in remote mode. - Check power to unit. - Do a Diagnostic Six communications test. 2) The unit acts on a message but gives no response back: Possible causes/remedies: - Using GLOBAL addressing without node 01 on the serial line. - Not waiting long enough for response. - The MicroLength transmit lines are not wired or are shorted. - More than one MicroLength with the same node address. - Do a Diagnostic Six communications test. Page - 40 (Version 2.0) (00.08.22) Appendix A: MicroLength 196 Program Record Factory default variable values (via Power-up with Software Reset; Diagnostic Seven Software Reset; Factory-Default Software Reset via serial communications): For your records, record Analog Output calibration voltages and any variables different from the default values. Control Name or Location ____________________________________ Var # Variable or Parameter Name Var01 Reference Length Var02 Reference Length Whole Revolutions Var03 Reference Length Additional Pulses Var04 Feedback PPR Var05 Feedback RPM @ 99% Output Var06 Batch Set Point Var07 Acceleration Time Var08 Deceleration Time Var09 High Speed Output Percent Var10 Creep Speed Output Percent Var11 Jog Speed Output Percent Var12 Settle Time Var13 Ideal Creep Time Var14 Integral Start Var15 Integral Correction Var16 User Label Var17 Display Selection Var18 Keypad Lockout Var19 Node Address Var20 Baud Rate Var21 Deviation Alarm Var22 Drive Enable Var23 Batch Total Var24 Cycle Count Var25 Feedback Frequency Var26 Creep Speed Time Var27 Position Error Var28 Resolution Var29 Kerf Addition Var30 Stop Correction Pulses Var31 Decel Correction Pulses Var32 Output Creep Time Var33 Last Cycle High Output % Var34 Last Cycle High RPM Var35 Minimum Set Point Length Var38 Cut-Delay Time Var39 Cut-ON Time Var47 Switch Enable in Remote Var48 Buffer Error Set Point 1 Set Point 2 Set Point 3 Set Point 4 Analog Output Calibration @ 0% Analog Output Calibration @ 99% Units (if any) user defined unit revolutions pulses pulses/rev RPM run-cycles/batch seconds seconds % % % seconds seconds pulses pulses batches run-cycles Hz seconds pulses user units/pulse user units pulses pulses seconds % RPM user units seconds seconds user units user units user units user units Volts DC Volts DC Default Values 000001 000001 000000 000060 001800 000010 0005.00 0005.00 000100 000010 000010 0001.00 0001.00 000005 000001 000001 000000 111111 000001 * 000002 * 000005 000001 000000 000000 000000 000000 000000 0.01667 000000 000045 000000 000000 000000 000000 159.000 0001.00 0001.00 000001 * 000000 180.000 180.000 180.000 180.000 0 10 Your Value (monitor only) (monitor only) ** (monitor only) (monitor only) (monitor only) (monitor only) (monitor only) (monitor only) (monitor only) (monitor only) (monitor only) (monitor only) (monitor only) (continued on next page) Page - 41 (Version 2.0) (00.08.22) Appendix A: MicroLength 196 Program Record (cont.): Var # Var49 Var50 Var51 Var53 Var54 Var55 Var56 Var57 Var62 Var63 Variable or Parameter Name New Set Point (serial only) Serial Status (serial only) Clear Batch Counter (serial only) Forward or Reverse (serial only) Set Point 1 (serial only) Set Point 2 (serial only) Set Point 3 (serial only) Set Point 4 (serial only) Display (serial only) Alarm Status (serial only) Units (if any) user units user units user units user units user units Default Values 000000 5xx000 *** 000000 000000 180.000 180.000 180.000 180.000 000.000 000000 Your Value (monitor only) (monitor only) (monitor only) (monitor only) Notes: * When a Factory-Default Software Reset via serial communications is done, the serial communication set-up variables (Vars 19, 20 and 47) do not get reset, but rather remain at whatever values they had. ** Var24 is a monitor variable, but one which the user can still enter in a value. Var24 counts-up from zero, or from whatever number the user has entered into Var24 (as long as it is less than the Var06 value). *** Var50’s default value depends upon the status of the ‘Local/Remote’ and ‘Set Point selection’ external switch inputs. -----------------------------------------------------------------------------------------------------------------Record any special Drive Calibration or miscellaneous notes here: ------------------------------------------------------------------------------------------------------------------ Power-up with Software Reset: All the MicroLength variables can be reset to factory-default values by doing a ‘Power-up with Software Reset’. A ‘Power-up with Software Reset’ can be done in two ways: 1) By holding-in both the ‘2nd Function ‘ key and the UP-ARROW key while powering-up. 2) By holding-in just the ‘2nd Function’ key while powering-up. Note: All the MicroLength variables can also be reset to factory-default values via ‘Diagnostic Seven Software Reset’ or ‘Factory-Default Software Reset via serial communications’. Page - 42 (Version 2.0) (00.08.22) Appendix B: Specifications Input Power: Line Voltage ............ 115 or 230VAC, 50/60 Hz Fuse .......................... 1/4 Amp Fast Blow 115VAC 1/8 Amp Fast Blow 230VAC Output Power: Encoder Supply .….. 12VDC, 250mA Maximum Unregulated Transducer (Encoder) Input: Wave Shape .............. Square, Sine Types ........................ NPN Open Collector PNP Open Collector Magnetic Pickup (Zero Crossing) Logic Level Maximum Input Freq. 15 KHz Internal Pull-up ........ 2.2Kohm, Pull-up to +12V Trigger Levels .......... 2.5VDC (NPN, PNP, Logic) 50mv (Zero Crossing) Other External Switch Inputs (Back-Panel): Sustained Contacts ... Forward/Reverse Keypad Lockout Set Point 1(3)/Set Point 2(4) Set Point 3 & 4 Enable Local/Remote Momentary .............. Batch Reset End Cycle Sustained, N.O. ....... Run at High Speed Basic External Switch Inputs (Back-Panel): Momentary, N.O. ..... Run Momentary, N.C. ..... Stop (Interrupt Cycle) Sustained, N.O. ........ Jog Momentary, N.C. ..... Emergency Stop Mechanical/Environmental Specifications: Enclosure Material ............. Cold Rolled Steel Keypad ...........................… Tactile Feedback Membrane, Chemical Resistant, Sealed Face Plate ......................... NEMA 4 Operating Temperature ...... 0 to 50 Degrees C Humidity ............................ 0 to 90%, Non-Condensing Weight .............................. 4.5 lbs. Back-Panel Transistor Outputs: NPN, Open Collector.. Batch Complete (Maximums Low Speed 50 VDC, Cut-Signal 250 ma, At Position 0.3 Watts) Deviation Drive Enable Analog Output: Type ........................ Span Adjustable ....... Offset Adjustable ..... Current .................... Resolution ............... Operational Specifications: Accuracy .......................... Plus/Minus One Pulse Preset Length Set Points .... Four Preset Batch Set Points ...... One Accel/Decel Times ........... User Programmable from 0.1 to 600 Secs. Processor .................…....... Intel 80C196TB 16 bit Microcontroller Upper Display .........…....... 6-Digit, 7-Segment LED, 0.36" Height Lower Display ...…..……… 8-Character, 5-7 Dot Matrix, 0.20" Height Function LEDs .................... 1 Run (green) 1 Stop (red) 1 Local (amber) 1 Remote (amber) 1 Set Point 1 (amber) 1 Set Point 2 (amber) Diagnostics/2nd Function ... Custom User Label Keypad Test Display Test Input Test Memory Test Output Test Serial Comm Test Return to Defaults Auto-Programming Digital Potentiometer Computer Interface ............ RS422 Interface Standard, 300 to 19200 Baud, 15 Char String, 1 Start, 8 Data, No Parity, 1 Stop Maximum Pulse Count …. . 2,147,500,000 Optically Isolated 0 to 10VDC 0 to 15 Volts -1 to +1 volts 10 ma Maximum Specifications Subject to Change Without Notice. 12 bit DAC Page - 43 (Version 2.0) (00.08.22) N.O. Momentary N.O. Momentary N.O. Sustained N.O. Momentary N.C. Momentary N.C. Momentary Page - 44 shield shield shield shield shield shield TB2 RXD- RXD+ TXD- TXD+ Isolated Command Output 10 15 1 2 5 3 TB1 2 3 4 5 6 7 8 9 20 19 17 16 14 13 11 18 12 TB2 Feedback (B) Freq Chassis Ground Shield Tie Terminals 4 +12V Feedback (A) Freq Run at High Speed Batch Reset StPt 1(3)/StPt 2(4) Keypad Lockout Forward/Reverse StPt 3&4 Enable Local/Remote End Cycle Jog Run Stop E-Stop 24 23 22 6 7 9 10 11 12 13 14 15 16 17 18 24 23 22 21 20 19 TB1 MicroLength 196 AT POSITION CUT-SIGNAL DEVIATION DRIVE ENABLE BATCH COMPLETE LOW SPEED MOTOR STATUS & ALARM OUTPUTS (NPN O.C.) 50VDC Max. 250 ma Max. 0.3 WATT Max. RS422/485 SERIAL COMM CONNECTIONS VARIABLE SPEED DRIVE DIODE PROTECT shield shield shield ENCODER Appendix C: Hookup Connection AC Line AC Neutral AC Ground (Version 2.0) (00.08.22) Appendix D: Normal and Abnormal Run-Cycles, Other run-cycle events: MicroLength Version 2.0 Normal events: (*1) A run-cycle is prevented from even starting, due to: - a ‘zero length Set Point’ (display reads “EntryErr”). - a ‘too short Set Point’ (display reads “HiSpdErr”). (*2) A complete straight run-cycle where Hi-Speed: - not reached - or if reached it was for less than 200 ms. (*2) Additional run-cycles not allowed, since the CV_HI_SPD_TIMER did not time-out on last-run (display reads “HiSpdErr”). A complete straight run-cycle at Hi-Speed for more than 200 ms. A complete run-cycle, where Hi-Speed reached (for more than 200 ms) after resuming from an interrupt-stop. A complete run-cycle where Hi-Speed: - not reached after resuming from an interrupt-stop. - or reached (but for less than 200 ms) after resuming from an interrupt-stop. Six (6) Abnormal events that abort a run-cycle: (*3) A run-cycle that runs (or at least dips) too slow during min-speed. (Display reads “LowFbkHz”, cycle may or may not reach Set Point length). Jog past Set Point length while at interrupt-stop. Reset while at interrupt-stop (via UP-ARROW key, or End Cycle switch input). Loss of feedback (display reads “NO FDBK!”). E-stop (display reads “E-STOP”). ‘Manual Run at Hi-Speed’ switch input closed during a run-cycle. Other events: ‘Manual Run at Hi-Speed’ switch input closed while in “READY” mode. Increment Var24 Cycle Count? (after run) Enter Correction Algorithm? (after run) Allow another run-cycle? Allow Cut-Signal operation? (after run) NO (can’t run) NO (can’t run) NO NO (can’t run) YES NO NO YES NO (can’t run) NO (can’t run) NO NO (can’t run) YES YES YES YES YES YES YES YES YES NO NO YES NO NO NO (*4) NO NO NO YES NO NO NO NO NO NO NO NO NO YES NO (*4) YES YES NO NO NO NO NO NO YES NO (* 1) Note: If this event happens, then the active Set Point length is less than the Minimum Set Point Length (either zero, or too short). The ‘MinSetPt’ is the shortest run-cycle theoretically possible that still allows the encoder to reach Var09 hi-speed for at least 200 ms. The uL196 calculates the ‘MinSetPt’ length corresponding to the Vars 01, 02, 03, 04, 05, 07, 08, 09, 10, and 13. - The ‘MinSetPt’ value corresponding to Vars 01, 02, 03, 04, 05, 07, 08, 09, 10, and 13 can be viewed in Var35 (monitor only). - Var35 MinSetPt is displayed using the same format and decimal point location as the active Set Point. - The active Set Point plus any Var29 Kerf addition must be equal to or greater than the value in Var35. - If the user enters a ‘too short Set Point’ (i.e., shorter than ‘MinSetPt’), then the MicroLength refuses to run the cycle. If the user must run such a short Set Point, they must first adjust the ref/set-up/ tuning vars; most likely lower Var09. Page - 45 (Version 2.0) (00.08.22) Appendix D: Normal and Abnormal Run-Cycles, Other run-cycle events (cont.): (* 2) Note: If this event happens, this is possible indication of either a POORLY CALIBRATED SYSTEM or an active Set Point length that is ‘too close’ to the Var35 MinSetPt value. (This because, the Microlength initially figured the Set Point was long enough to reach Var09 hi-speed for at least 200 ms, but the actual run-cycle proved otherwise). The run-cycle must reach Var09 hi-speed for at least 200 ms for the internal CV_HI_SPD_TIMER to time-out, if not, then future runs are prevented. The user must do one of the following actions to manually clear the internal CV_HI_SPD_TIMER back to zero: a) Change at least one of the ref/set-up/ tuning Vars 01, 02, 03, 04, 05, 07, 08, 09, 10, 13. Most likely lower Var09. b) Check/Recalibrate the Microlength’s Analog Output. (Insure that when the “Pot % = 99” the encoder turns at the maximum desired speed. Enter into Var05 the maximum speed obtained when the “Pot % = 99”). Note for (a) and (b): Since Var35 MinSetPt is a theoretical value, marginal run-cycle accuracy/repeatability may be experienced for active Set Point lengths that are ‘too close’ to the Var35 MinSetPt value. After doing step (a) or (b), recheck the Var35 value. If the Var35 MinSetPt value is ‘too close’ to the Set Point length, try lesser values in Vars 07, 08, 09, 10, or 13. (This may improve run-cycle performance by lessening the Var35 MinSetPt value). c) Press the 2ND FUNC key twice. This allows another run, but doesn’t fix the Var09 hi-speed problem. d) Change any Set Point (active or non-active) via keypad, serial, or external switch input. This allows another run, but doesn’t help in reaching the initial desired Set Point length. (* 3) Note: If this event happens, then this is a possible indication of a POORLY CALIBRATED SYSTEM. a) Try increasing Var10 (creep speed) slightly. b) Insure that the motor drive's internal accel/decel settings are set for the fastest/shortest/quickest times. c) Check/Recalibrate the MicroLength’s Analog Output. (* 4) Note: A ‘Stop’ command clears a “LowFbkHz” or “NO FDBK!” error. (Sometimes must push UP-ARROW key also). 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