Profiler IV Feed Back Version DC Motor Control Board with Current Profiling Capability Variable travel length version

Transcription

1 Profiler IV Feed Back Version DC Motor Control Board with Current Profiling Capability Variable travel length version The Profiler IV is a DC Motor Control board designed specifically for Motion Systems Corp. motor drives. This innovative new control board provides safe, intelligent bi-directional control for brush type DC motor drives up to 20 Amps. What sets the Profiler IV apart from other motor drives is its intelligent, self-learning and adjusting operation. The Profiler IV actually learns the characteristics of the drive system in just one simple operation. The Profiler IV automatically builds two point power verses position profiles (see figure 1), one for each direction of travel. The profiles are a direct representation of the DC motor drive s characteristics for each direction of travel. These profiles are then stored permanently in nonvolatile memory, and are used as a dynamic reference for over-current shut down (see figure 2). 60 Motor Power Usage Power verses Position profile Figure 1 Lift Position Motor Power Usage Over-current trip level Power verses Position profile Figure 2 Lift Position

2 The Profiler IV s Power Profiling technology provides for very sensitive blockage protection with no external sensors. This keeps the cost and complexity of the system to a minimum. The over-current trip level directly correlates to the power verses position profile. This allows for very sensitive trip protection without affecting the reliability of the motor drive system. The over-current trip protection feature will stop the motor drive and reverse direction if a trip event occurs. This is done to prevent injury and allow for the path to be cleared should an object obscure the normal path of operation. The Profiler IV is designed specifically for Motion Systems Corp. motor drives with end of travel free-run capability. This creates a failsafe, allowing the motor to free-run when the end of travel is reached in either direction without damaging the mechanics of your system or the motor drive. Use of the Profiler IV with non free-run motors is not recommended. The Profiler IV also soft starts and stops the DC motor in each direction. The soft start and stop feature uses pulse width modulation to ease the motor into and out of motion in both directions. This soft start and stop greatly increases the motor brush life and provides smooth system startup and stop performance. The system is operated using a single momentary push button switch. Simply press and release the control button and the motor will soft start, run in one direction, and then ease to a stop. Press the button again and the motor will soft start, run in the other direction, and then ease to a stop. That s it; the Profiler IV does the rest. The Profiler IV also has several additional features. 1. On the fly storage of system control settings. This means that once the system is setup, it should never need to be changed again do to power outages. The controller remembers all control states and values so if power is removed, the controller picks up where it left off before power was removed. Note: as a safety feature, the controller will never power up in motion. The control button must be pressed after power is reapplied and the controller will return to the direction it came from and is then ready for service again. 2. Position tracking continually monitors lift position. The position information is independent of vehicle supply voltage so the lift always knows the correct position value. This allows the lift to operate from 9 to 24 volts without ever falling short of fully opening or closing. 3. Neutral lockout monitors the neutral sense switch in the vehicle. The neutral sense switch is used to make lift conform to D.O.T. regulations. For example, if the vehicle is put into drive while lift is open the lift will sound a series of beeps as a warning and then close. Lift will remain closed until vehicle is placed into park. Once in park lift will return to normal operation again. 4. Manual setup mode for easy installation. The manual setup mode allows the installer to manually move the lift as needed in any amount. To enter manual setup mode simply press and hold the set button for 15 seconds. The controller will respond with a series of tones. Once the tones are heard release the set button. Now a press of the control button, and the lift will run in one direction until control button is released. Another control button press and the lift will run in the other direction until the control button is released. To exit manual setup mode, simply press and hold the set button for 7 seconds and the controller will sound a series of tones confirming the request. The controller will also exit manual setup mode automatically after 15 minutes of inactivity. To learn more about manual setup mode, please see the alignment section of this manual. 5. Blockage trip in manual and profile modes. If lift travel is blocked during the profiling procedure the lift will stop motion and sound a series of alarm tones and enter manual mode. The lift will also trip in manual mode. If lift travel is blocked in manual mode the lift will stop and sound a series of alarm tones and stay in manual mode.

3 Setup Procedure The controller is very easy to initially setup. Simply connect the controller to power, motor drive, and remote switchboard. Then press and hold the set button, then press and hold the control button, finally, release both buttons after two seconds. The controller will emit two beeps and the motor should soft start and run until it reaches the end of travel and emit two more beeps. Repeat this process for the other direction of travel. The setup for both directions is now completed. This completes the setup procedure. The controller is now ready for service and should not need setup again. If the drive system is changed or you desire to change the setup simply follow the above procedure again. The control board is shown below. There is a trimmer pot located on the board that is used to set the over current trip threshold. The trip threshold is adjustable from 0 to 255. This allows you to set the trip threshold as close to or far away as you desire from the current profile. Simply stated, the trip threshold setting varies the system s sensitivity to a possible blockage. The trip sensitivity increases by turning the trimmer pot clockwise and decreases by turning trimmer pot counter clockwise. Trip sensitivity control trimmer

4 ELECTRICAL CONNECTION DIAGRAM Power connector Neutral lockout/monitor control connector Motor drive feedback connector Motor connector Remote control connector Remote breakout board Normally open momentary set switch Normally open momentary control switch + Piezo buzzer The electrical connections shown above are for a typical installation. All switch connections are made with 1/4 inch spade lug crimp connectors. The set switch is normally left disconnected or placed in a hidden location. The control button can be placed anywhere it s required.

5 Manual Mode Operation 1. Manual mode is used to setup the new variable travel length feature. This new feature allows the travel lengths of the drive to be changed to compensate for variations that can accrue during the installation process. 2. To enter Manual mode, simply press and hold the set button on the remote board for 15 seconds. You will hear a series of long/short tones to let you know that you have entered manual mode. Release the set button when tones are heard. 3. The new variable travel Profiler drives use a new 4 button remote board for setup. This new control board incorporates two slow motion control buttons. These new slow motion buttons allow the drive to be very precisely positioned while in manual mode. Slow open Button Set button Slow close button Control button 4. To change the travel lengths, position drive to the new open or close position using the slow motion buttons as well as the control button. When the drive is positioned properly. Press and hold the set button then press and hold the control button then release then both when a 4 tones are heard. The 4 tones inform the installer that the end of travel position has been stored correctly. 5. The end of travel may be changed for both directions of travel. Simply repeat step 4 for the other end of travel. Note: It is not necessary to set both ends of travel. If only one end point needs changed then set only one end of travel point. 6. With the end of travel points set. You may exit manual mode two ways. First way is to press and hold just the set button for 8 seconds. The other way is to allow the unit to time out. This time out takes 15 minutes. 7. The Profiler board will need to be profiled again to create a new matching profile for both directions of travel.

6 8. To profile the drive simply press and hold the set then press and hold the control button then release both buttons when two tones are heard. The lift should start motion and stop abruptly and beep twice when the new end of travel is reached. Repeat this procedure for the other direction of travel. 9. This completes the setup procedure. The lift should now operate with the new end of travel points. The lift should not requite any further adjustment. Remote Serial control cable wiring TO PROFILER IV PCB NEUTRAL LOCKOUT LINE TO SERIAL PORT ON AMX SYSTEM JP MINI MOLEX YELLOW WHITE BROWN RED GROUND RX DATA INPUT TO PCB TX DATA OUTPUT FROM PCB P1 REMOTE CONTROL SERIAL CABLE 9600 BAUD 8,N,1 CONNECTOR DB9 MAIL LIFT WILL ONLY OPEN WHILE CLOSED AFTER RECPTION OF A (* AND THE RAW HEX VALUE OF $AA) LIFT WILL ONLY CLOSE WHILE OPEN AFTER RECEPTION OF A (* AND THE RAW HEX VALUE OF $55) ALL LIFT FUNCTIONS VIA. REMOTE BREAKOUT BOARD ARE UNAFFECTED BY REMOTE SERIAL CONTROL FEATURE. Factory Calibration Mode The control board also includes a factory calibration mode. This mode is used only when a control board or a motor drive is replaced. To enter factory calibration mode, remove power from control board. Then press and hold the set and control buttons and apply power to control board continue holding until a slow steady series of beeps is heard. When Beeps are heard release set and control buttons. Make sure that the lift has freedom of movement in both directions of travel. Press the control button once and the lift will beep and run fully in both directions then stop. The controller is now ready for the setup procedure on page 3.