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Operating Manual CMGZ 622

Digital Tension Controller

for double range force sensors

Version 1.25

01/2011 ff

Firmware Version 1.07

Hardware Rev. D

This operation manual is also available in German.

Please contact your local representative.

Diese Bedienungsanleitung ist auch in Deutsch erhältlich.

Bitte kontaktieren Sie Ihre nächstgelegene FMS Vertretung.

Summary of Contents for CMGZ 622

Page 1: ...mware Version 1 07 Hardware Rev D This operation manual is also available in German Please contact your local representative Diese Bedienungsanleitung ist auch in Deutsch erh ltlich Bitte kontaktieren...

Page 2: ...r the drive unit 16 8 5 Mounting the distance sensor 17 9 General Operation 18 9 1 View of the Operating Panel 18 9 2 Calibrating the Measuring Amplifier 20 9 3 Setup the PID Controller 22 9 4 Enterin...

Page 3: ...58 16 1 Wiring of the PROFIBUS Data Cable 58 16 2 Setting the PROFIBUS Address 58 17 PROFIBUS Interface Description 59 17 1 GSD File 59 17 2 CMGZ622A DP Slave Functional Description 59 17 3 Initial P...

Page 4: ...cause electric shock to persons malfunction of the total system or damage of the electronic unit It is vital to ensure that proper earth connection is done The processor board is mounted to the housi...

Page 5: ...ubprint used for a certain purpose There can be up to four channels in a single electronic unit Module The software running on the microprocessor is spread over various function units modules A module...

Page 6: ...rol supported External diameter or line speed signal can be processed an added to the output value Integrated brake amplifier With operation panel for parametrization With robust aluminium housing Sup...

Page 7: ...tal input selects the measuring range to be used for the control loop If the material tension deviates too much the brake or the drive will be activated more ore less depending on configuration 4 2 Fo...

Page 8: ...ables break automatically and to output an error message if required A highly accurate fixed difference amplifier rises the mV signal up to 10V This signal will be fed to the A D converter The micropr...

Page 9: ...without brake amplifier a separate power amplifier has to be used The power amplifier drives the brake corresponding to the output signal of the electronic unit Any power amplifier for brakes can be u...

Page 10: ...rift away Due to that it has high long time and temperature stability This feature also allows to exchange an electronic unit without readjusting P component A controller with only a proportional comp...

Page 11: ...st run with low speed and low material tension Input reference value ref to 9 5 Inputting the reference value Enable controller ref to 9 8 Automatic operation Determine PID control parameters and set...

Page 12: ...Operating Manual CMGZ 622 12 7 Dimensions fig 4 Dimensions C600005e Type Housing size CMGZ622 standard CMGZ622 B big...

Page 13: ...pment They are not taken into consideration in this operating manual However they have to be followed strictly Caution Bad earth connection may cause electric shock to persons malfunction of the total...

Page 14: ...equipment Don t use rough tools such as screwdrivers or pliers Touch processor board as little as possible Touch earthed metal part to discharge static electricity before open the housing fig 6 Screw...

Page 15: ...Operating Manual CMGZ 622 15 8 2 Wiring Diagram CMGZ622 fig 8 Wiring diagram CMGZ622 C622003e input power 24V DC fig 9 Wiring diagram for integrated brake amplifier CMGZ B C600004e...

Page 16: ...r signal and signal Note Connecting the shield of the signal cable to the electronic unit and to the force sensor may cause ground circuits which may interfere the measuring signal massively Malfuncti...

Page 17: ...and Tension Controllers fig 10 Mounting of the distance sensor CMGZ581924 E411012e The distance sensor operates with the 3 beam correction principle It is considerable insensible to secondary light a...

Page 18: ...Operating Manual CMGZ 622 18 9 General Operation 9 1 View of the Operating Panel fig 11 Operating panel CMGZ622 C622008e fig 12 Main operating menu CMGZ622 C622005e...

Page 19: ...e ref to nameplate of the force sensor Nominal force 2 High nominal force ref to nameplate of the force sensor Unit of sensor Ref to nameplate of the force sensor Sensitivity FMS force sensors 1 8mV V...

Page 20: ...eck if a positive value is displayed when loading the sensor in measuring direction If not exchange terminals signal and signal on the measuring amplifier Find offset Insert material or a rope loosely...

Page 21: ...n value will be calculated by the following formula and then inputted in the parameter Gain feedback refer to 14 5 Description of the parameters CMGZ622 fig 14 Force vectors in the FMS force measuring...

Page 22: ...required reference value range refer to 14 Parametrization Set the value of the voltage source according to the required reference value 9 5 Determination of the control parameters Experimental deter...

Page 23: ...or all 4 sets of parameters But for better understanding the instruction is written in common form There is a specific parameter set active depending on Measuring Range and PID switched or not The ref...

Page 24: ...clude a bit of reverse running Then the material tension is increased to the reference value or the pilot control value depending on parameter Pilot control refer to 14 Parametrization Operating a bra...

Page 25: ...oller are used where the dynamics of a PI controller is not enough The D component causes greater tendency to instable behaviour than using a PI controller The parameter PID configuration is set to PI...

Page 26: ...of parameters Limit 1 min max Limit value 1 Limit 2 min max Limit value 2 ref to 14 Parametrization Tapping of the limit switches is done according to wiring diagram Control Error Limitation The para...

Page 27: ...ng to your requirements refer to 10 2 Inputting the holding torque Note There is one additional analogue input for external reference diameter or line speed signal You cannot run the controller with e...

Page 28: ...he actual reel diameter to the electronic unit an analog signal 0 10V from a distance sensor or other source is fed to the analog input terminals Signal 0 10V and Signal Gnd refer to wiring diagram Di...

Page 29: ...actual output value can be read from the display fig 10 Note these values Actual reference value REF ________________ N lbs Actual output value OUTPUT ________________ V mA Terminate test run Calculat...

Page 30: ...adjustment of pilot control is lost If one of these parameters are changed after pilot control already being adjusted you have to proceed again for adjustment of pilot control Partition the output int...

Page 31: ...must decide which signal you want to process with the controller and then set the parameters Reference source and Pilot control accordingly Now continue with section 9 5 Inputting the reference value...

Page 32: ...t speed For the time being set to 0 00 Start limit For the time being set to 0 0 Note There is one additional analogue input for external reference diameter or line speed signal You cannot run the con...

Page 33: ...variations This will increase control loop stability Setup of pilot control is done as written under 10 3 Setup of pilot control 12 4 Taper Function fig 18 Characteristic curve of the taper function C...

Page 34: ...must decide which signal you want to process with the controller and then set the parameters Reference source and Line speed overlay accordingly Now continue with section 9 5 Inputting the reference v...

Page 35: ...the controller being able to drive the drive roller correctly the output signal has to be set in relation to the diameter and speed of the drive roller Drive the drive unit with a certain output valu...

Page 36: ...anging mode is activated by pressing the PARA key for 3 seconds The required module is then searched with the keys and selected with the PARA key fig 19 Each module has its own parameter set Generally...

Page 37: ...b u w l 0 100 9 000 1 000 Nominal force 1 b u w l N kN cN 1 9999 1000 Nominal force 2 b u w l N kN cN 1 9999 1000 Unit of sensor b u w l N kN cN N Sensitivity b u w l mV V 0 1 3 0 1 8 1 or 2 force sen...

Page 38: ...roportional P4 b u w l 0 01 100 00 1 00 Integral I4 b u w l s 0 01 100 00 1 00 Derivative D4 _ u w l s 0 001 10 000 0 010 Error limit b u w l 1 0 100 0 100 0 Alarm control error b u w l 0 1 100 0 10 0...

Page 39: ..._ 4 5 1 Code refers to b unwind brake u unwind drive w winding drive l line drive 2 N cN kN if measuring system metric lb clb klb if measuring system US standard 3 A force value can be input The value...

Page 40: ...ovides a lowpass filter to prevent noise which is added to the integrated display This parameter stores the cut off frequency The lower the cut off frequency the more sluggish the output signal will b...

Page 41: ...Winding drive Line drive Use This parameter stores the value in Digit determined with special function Find offset while the digital input switch range was OFF measuring range 1 It is not necessary t...

Page 42: ...ed using the formulas written under 9 3 Calibrating the measuring amplifier if the material tension cannot be simulated Range 0 100 to 9 000 Default 1 000 Increment 0 001 Unit Nominal Force 1 Applies...

Page 43: ...drive Line drive Use The electronic unit provides a lowpass filter to prevent noise which is added to the feedback signal This parameter stores the cut off frequency The lower the cut off frequency th...

Page 44: ...his parameter acts to the digital output limit value 2 Range Min Max Default Min Limit value 2 Applies to Unwind brake Unwind drive Winding drive Line drive Use Identical with Limit value 1 but this p...

Page 45: ...p of pilot control Range No Yes Default No Line speed overlay Applies to Line drive Use If this parameter is set to Yes the actual line speed signal is overlayed to the PID controller output This will...

Page 46: ...anged while the controller is enabled The new value is taken for the control loop when quit parameter mode There are 4 different P values available P1 P4 The BCD digital inputs are used for switching...

Page 47: ...eding this range are limited to the range Thus extreme peaks of the control output value are avoided in case of high variations of the tension feedback value i e with rough running reels This allows t...

Page 48: ...8V or 0 8V or 0 16mA or 4 16 8mA depending on parameter Output config Due to that a current limitation for the brake power can be realized indirectly For the CMGZ B with integrated brake amplifier op...

Page 49: ...force sensors ref to fig 1 Depending on the position the polarity of the output value is different Range After sensor Before sensor Default After sensor Ramp diameter Applies to Unwind brake Unwind d...

Page 50: ...nwind drive Winding drive Line drive Use This parameter defines which force value is assigned to a 10 V signal on the analog reference input if measuring range 2 is used digital input switch range ON...

Page 51: ...10 of 10V 1 0V Range 0 0 to 100 0 Default 0 0 Increment 0 1 Unit Out Taper function Applies to Winding drive Use This parameter defines the shape of the characteristic curve for the taper function ref...

Page 52: ...here is output with negative sign for ex 5 will result in an output signal of 0 5V Range 0 00to 100 00 Default 0 00 Increment 0 01 Unit Out Start limit Applies to Unwind drive Winding drive Use Descr...

Page 53: ...plies to Winding drive Line drive Use This parameter stores the diameter of the drive roller It is used for the line speed overlay function and for the taper function Range A diameter value can be inp...

Page 54: ...ervice mode parameters may result in heavy malfunctions Therefore these settings should be made by specially trained personnel only The service mode is activated by pressing the and keys for 3 seconds...

Page 55: ...This parameter stores the first diameter value given with special function Adjust diameter Range A diameter value can be input The value consists of 4 digits Unit mm or inch Cal dia signal 1 Applies t...

Page 56: ...rence value corresponding to the parameter Pilot output The value is determined with special function Adjust pilot control Range A force value can be input The value consists of 4 digits The position...

Page 57: ...Operating Manual CMGZ 622 57 15 Serial Interface RS232 Optional...

Page 58: ...sured that the two termination dip switches are in off position If only one cable is connected Bus in both termination dip switches have to be set in on position main board 9 9 9 9 Profibus J802 PG A...

Page 59: ...rwise there may be problems while setup Version numbers of firmware and GSD file are printed to the cover page of this operating manual 17 2 CMGZ622A DP Slave Functional Description The tension contro...

Page 60: ...r to the control system in each data cycle Byte 0 Byte 1 Byte 2 Byte 3 request telegram master slave function code channel number empty empty response telegram slave master function code or error FFh...

Page 61: ...ference tension controller 03h Controller Error controller error tension controller 04h Output output tension controller 07h A D value brutto A D value tension controller The tension controller transm...

Page 62: ...Operating Manual CMGZ 622 62 18 Interface CAN Bus Optional...

Page 63: ...ED dig input 3 D411 Status LED dig input 4 J200 Reserved J201 Reserved J203 Reserved J402 405 Solder bridges for dig output 1 4 open collector J500 Add on board for dig I O J800 Socket subprint PROFIB...

Page 64: ...rminal for dig output 9 16 relay J309 316 Jumper for dig output 9 16 relay J400 401 8 x Terminal 24VDC J500 J509 Terminal for dig output 1 8 open collector J501 508 Solder bridges for dig output 1 8 o...

Page 65: ...malfunction of the electronic unit or the total system Setting of the solder bridges and jumpers must be checked carefully prior to power on Setting of the solder bridges should be carried out by tra...

Page 66: ...closed J1205 J205 closed closed open Setting the sensor signal solder bridges Channel 1 main board Channel 2 4 subprint Sensor signal 12 5 or 25mV default Sensor signal 0 10V J1201 J201 open1 closed1...

Page 67: ...on A D converter 8192 Digit 14 Bit Measuring error 0 05 FS Cycle time 2ms Operation 4 keys 4 LED s LCD display 2x16 characters 8mm height Analogue output channel 1 4 0 10V default 10V and 0 20mA defau...

Page 68: ...n channel n is 0 even though material is loose Current output is set to 4 20mA Adjust channel parameter config output if a signal 0 20mA is required If current output shows 10 12mA Jumper for tension...

Page 69: ...ort circuit Check force sensors and wiring of channel n C n Cable break Excitation of channel n detects cable break Check force sensors and wiring of channel n C n HW error Hardware of channel n defec...

Page 70: ...rrect depending on the brake used Pilot control does not work as expected Setup of pilot control failed Repeat setup of pilot control ref to 10 3 Setup of pilot control Brake doesn t brake Fuse blown...

Page 71: ...r signal gives 0 diameter sensor defect Check diameter sensor and wiring replace if needed Pilot control does not work as expected Setup of pilot control failed Repeat setup of pilot control ref to 10...

Page 72: ...FMS USA Inc 2155 Stonington Avenue Suite 119 Hoffman Estates IL 60169 USA Tel 1 847 519 4400 Fax 1 847 519 4401 fmsusa fms technology com FMS UK Highfield Atch Lench Road Church Lench Evesham WR11 4U...

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