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Operating Manual CMGZ411/421

Digital microprocessor controlled tension control unit

V2.01 05/04 sd

This operation manual is also available in German.

Please contact your local representative.

Diese Bedienungsanleitung ist auch in Deutsch erhältlich.

Bitte kontaktieren Sie die Vertretung im zuständigen Land.

Summary of Contents for CMGZ411

Page 1: ...01 05 04 sd This operation manual is also available in German Please contact your local representative Diese Bedienungsanleitung ist auch in Deutsch erhältlich Bitte kontaktieren Sie die Vertretung im zuständigen Land by FMS Force Measuring Systems AG CH 8154 Oberglatt All rights reserved ...

Page 2: ...tal system or damage of the electronic unit It is vital to ensure that proper earth connection is done Caution The processor board is mounted directly behind the operation panel Improper handling may damage the fragile electronic equipment Don t use rough tools as screwdrivers or pliers Don t touch processor board Touch earthed metal part to discharge static electricity before removing operation p...

Page 3: ...of measuring amplifier 17 9 1 Initial operation of measuring amplifier CMGZ411 17 9 2 Initial operation of measuring amplifier CMGZ421 18 9 3 Correction input CMGZ411 19 10 Initial operation of PID controller 20 10 1 Parametrization of the PID controller 20 10 2 Determination of PID control parameters 20 10 3 Enable controller 21 10 4 Controller lock 21 10 5 Setting of tension reference 22 10 6 Ti...

Page 4: ...ial functions CMGZ411 Gain switching For applications with different wrap angles the gain factor can be changed easily using a digital input Correction input For applications with continuously varying wrap angles i e at winders unwinders directly the CMGZ411 provides a 0 10V input for the continuous correction The correction signal usually is obtained from a PLC or from a potmeter that is mounted ...

Page 5: ...Operating Manual CMGZ411 421 5 3 3 Block Diagram CMGZ411 C411000e 3 4 Block Diagram CMGZ421 C421000e ...

Page 6: ...also equals to zero A small error only can create a small output signal which is not high enough to compensate the complete error That means that a controller with only a proportional component will have a steady error depending on the p factor The characteristic value for a P controller is the proportional factor Xp I Component A controller with an integral component integrates the error signal c...

Page 7: ...ection Application In applications where you need only low dynamic response it is possible to use 1 quadrant drives If a machine not only has to accelerate fast but also has to decelerate fast it is necessary to use a 4 quadrant drive to switch from driving to braking immediately Only a 4 quadrant drive is able to handle both processes A brake would be able to help in the deceleration process but ...

Page 8: ...e v i r D C D e k a r B d e e p S d e l l o r t n o c e v i r D C D y c n e u q e r f C A h t i w r e t r e v n o c t i n u e k a r B e u q r o T d e l l o r t n o c e v i r D C D y c n e u q e r f C A r e t r e v n o c r t n o c r o t c e v d e e p S d e l l o r t n o c e v i r D C D y c n e u q e r f C A r e t r e v n o c 0 0 4 Z G M C 1 g i f n o c 0 0 4 Z G M C 2 g i f n o c 0 0 4 Z G M C 4 3 ...

Page 9: ...Operating Manual CMGZ411 421 9 7 2 Determination of the machine configuration C400001e ...

Page 10: ...Operating Manual CMGZ411 421 10 C400002e ...

Page 11: ...Operating Manual CMGZ411 421 11 C400003e ...

Page 12: ...Operating Manual CMGZ411 421 12 C400004e ...

Page 13: ...Operating Manual CMGZ411 421 13 C400005e ...

Page 14: ...ts It is also important to ground the gnd terminal of the controller only to a single point The Ground terminals of the controller and the reference input of the drive resp brake unit are connected Caution Bad earth connection may 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 Digital input...

Page 15: ...right side Caution The processor board is mounted directly behind the operation panel Improper handling may damage the fragile electronic equipment Don t use rough tools as screwdrivers or pliers Don t touch processor board Touch earthed metal part to discharge static electricity before removing operation panel Danger Some contacts of the 230VAC version are under 230V tension Mortal danger Disconn...

Page 16: ...contr err 28 Dig In 4 reserved 26 Dig Out limit value 1 29 Dig Out controller ok 27 Dig Out limit value 2 30 Dig Out alarm contr err 28 Analog Out Dig Out limit value 1 29 Controller out 0 10V 12 Dig Out limit value 2 30 Controller out 0 4 20mA 13 Analog Out Controller out Gnd 14 Controller out 0 10V 12 Feedback 0 10V A B 15 Controller out 0 4 20mA 13 Feedback Gnd 18 Controller out Gnd 14 Feedback...

Page 17: ...ack with or keys Press key for 3 seconds The electronic calculates automatically the offset value and stores it under parameter Value offset feedback Load material or rope with a defined weight Select parameter Calibration Feedback with or keys and confirm with key Input the force referring to the applied weight with keys and confirm with key The electronic calculates automatically the new gain va...

Page 18: ...ation Feedback channel A with or keys and confirm with key Input the force referring to the applied weight with keys and confirm with key The electronic calculates automatically the new gain value and stores it under parameter Value gain feedback channel A Select parameter Calibration Feedback channel B with or keys and confirm with key Input the force referring to the applied weight with keys and...

Page 19: ...rection The adjustment is made by choosing 3 positions within the used correction range Search parameter gain cosine at U1 and press the key Change the value in the display in this position with the keys until the effective value is displayed Save the gain and voltage values with key The display shows now gain cosine at U2 Change now to the second position and press key Change the shown value in t...

Page 20: ...rlay 10 2 Determination of PID control parameters Mathematic determination of control parameters To calculate the parameters for the controller the well known equations of Bode Ziegler Nichols or others can be used The values calculated by the appropriate formulas can be entered under the parameters PID configuration Proportional component P Integral component I Derivative component D After that t...

Page 21: ...roller ok is activated With configuring the parameter Start limit to 0 this behaviour can be suppressed and the controller begins to operate immediately Although this is possible it is advisable to use a value greater than zero because this starting procedure takes only fractions of a second if there is no slack material If a 1 Q drive is used as an unwinder the starting procedure is inactive as t...

Page 22: ...for the control loop continuously But the tension reference can be given also by interface or by analogue input 10 6 Time flow of the signals using a control loop with drive C400006e 11 Serial interface RS232 The serial interface is operated for example by a personal computer as a kind of question and answer game The PC sends a question resp a command the electronic unit will send an answer back I...

Page 23: ...e Sub D connector 11 2 Command list Command Answer from controller Purpose IDNT CR CMGZ 411 V 1 00 0895 10 characters type fixed Typ Version S 10 characters version fixed 4 characters serial number fixed DAKT CR XXXXX CR read actual diameter CMGZ411 DIFF CR DIFY CR DIFN CR alarm controller error DIFR CR DIFRXXXX X CR alarm controller error in ERR CR XXXXXX CR ask for eventual errors 1st digit 1 Er...

Page 24: ... CR FAIL CR value gain 1 channel A WP06X XXX CR PACC CR FAIL CR value gain 1 channel B CMGZ 421 WP07XXXX CR PACC CR FAIL CR nominal force WP08X CR PACC CR FAIL CR unit force WP09X X CR PACC CR FAIL CR sensitivity WP10X CR PACC CR FAIL CR 1 or 2 sensors WP11XXX X CR PACC CR FAIL CR filter feedback WP12XX X CR PACC CR FAIL CR filter instrument A B WP13XX X CR PACC CR FAIL CR filter instrument A CMGZ...

Page 25: ...49X XXX CR PACC CR FAIL CR gain cosine at U3 CMGZ 411 WP50XXX CR PACC CR FAIL CR identifier WP51XXXX CR PACC CR FAIL CR Baud rate interface WP52X CR PACC CR FAIL CR Data bit interface WP53X CR PACC CR FAIL CR Stop bit interface WP54X CR PACC CR FAIL CR Parity interface 11 4 Read parameters Command Answer Purpose RP01 CR XXXXX CR offset feedback channel A RP02 CR X XXX CR gain feedback channel A RP...

Page 26: ...CR tension reduction CMGZ 411 RP42 CR X XXX CR reduction value CMGZ 411 RP43 CR XXXXX CR scal poti reference CMGZ411 RP44 CR X CR correction input CMGZ 411 RP45 CR XX XXX CR linear correction at 0 VDC CMGZ 411 RP46 CR XX XXX CR lineare correction at 10 VDC CMGZ 411 RP47 CR X XXX CR gain cosine at U1 CMGZ 411 RP48 CR X XXX CR gain cosine at U2 CMGZ 411 RP49 CR X XXX CR gain cosine at U3 CMGZ 411 RP...

Page 27: ...tional component P 1 00 0 01 50 00 ________ Integral component I s 1 00 0 01 100 00 ________ Derivative component D s 0 010 0 001 10 000 ________ Alarm limit error 10 0 0 1 100 0 ________ Maschine configuration 1 1 23 ________ Output configuration 0 10V 0 20mA 4 20mA 10V ________ Start speed output 0 00 0 00 50 00 ________ Start limit reference 90 0 0 0 100 0 ________ Synchronisation stop No Yes _...

Page 28: ...______ Lowpass display Hz 1 0 0 1 10 0 ________ Scale instrument A B 0 50 0 01 10 00 ________ Scale instrument A 1 00 0 01 10 00 ________ Scale instrument B 1 00 0 01 10 00 ________ Limit 1 min max 0 0 1 ________ Limit value 1 N KN 0 9999 9999 ________ Limit 2 min max 1 0 1 ________ Limit value 2 N KN 0 9999 9999 ________ Language D German E English F French I Italian ________ Ramp reference s 1 0...

Page 29: ... is corresponding to the loaded weight web tension when cosine correction is active The microprocessor calculates a gain factor in the background which will result a changed display value The gain factor is changed by the up and down keys If the effective value is shown the gain factor and the referring input voltage are stored with key Proceed with Calibration gain cosine at U2 Calibration gain c...

Page 30: ... Value gain 1 feedback Purpose This parameter allows to show the gain factor set under Calibration gain 1 feedback or to enter a gain factor calculated by the formula refer to initial operation Range 0 100 to 9 000 Default 1 000 Increment 0 001 Nominal force of sensors Purpose To get a display value according to the actual force in the machine it is necessary to enter the nominal force of the sens...

Page 31: ...he signal conditioned with this filter drives a 0 10V analog output signal With this parameter the cutoff frequency is set in Hz Range 0 1 to 10 0 Default 1 0 Increment 0 1 Unit Hz Lowpass display Purpose The control unit provides a low pass filter for the display to get stable values in the display This cutoff frequency is independent of the feedback lowpass Range 0 1 to 10 0 Default 1 0 Incremen...

Page 32: ...o 9999 Default 0 Increment 1 Unit N kN Language Purpose With this parameter the language in the display can be chosen Range German G English E French F Italien I Ramp reference Purpose To optimize the controller regarding to disturbance characteristics changes of the reference value must not be too fast Therefore the tension reference is led internally over a ramp Its rate of rise is adjusted with...

Page 33: ...he sensors Range 0 1 to 100 0 Default 10 0 Increment 0 1 Unit Machine configuration Purpose The machine configuration depends on the arrangement as winder unwinder intermediat drive or brake to get correct feedback signal for all of these conditions The selection is easy with the illustrations in chapter 7 Range 1 to 23 Default 1 Increment 1 Unit Output configuration Purpose This parameter allows ...

Page 34: ...onisation stop is active the controller will control until output has reached 0V Range No Yes Default No Line speed overlay CMGZ411 Purpose This parameter gives the percentage quota of the controller output which will be overlayed to the line speed Common value is 10 Range 0 0 to 100 0 Default 00 0 Increment 0 1 Unit Line speed tacho CMGZ411 Purpose Stores the revolutions per minute that will rise...

Page 35: ...in diameter For tension reduction refer to chapter Parametrization of the PID controller Range 0 000 to 1 000 Default 0 000 Increment 0 001 Unit N kN Scal potmeter reference CMGZ411 Purpose Stores the tension value that will correspond to a signal of 10V at the analogue input terminals d6 d8 Range 0 to 9999 Default 0 Increment 1 Unit N kN Correction input CMGZ411 Purpose This parameter is uesd if ...

Page 36: ...he value calculated with parameter Gain cosine at U1 U U3 Range 0 001 to 9 999 Default 1 000 Increment 0 001 Unit Identifier Purpose This parameter identifies the CAN BUS Interface Reserved for future use Baud rate Purpose Configuration of the transmission rate of the RS 232 interface 300 600 1200 2400 4800 9600 baud Range 300 to 9600 Default 9600 Data bit Purpose Configuration of the RS 232 inter...

Page 37: ...tor adjusted can be seen under Parameter Value gain 1 channel A resp Value gain 1 channel B Gain switching is activated by digital input 3 terminal b6 Lowpass instrument A B CMGZ421 Purpose The control unit provides a low pass filter for the tension feedback to suppress noise caused by unbalanced rollers or interference The signal conditioned with this filter is used for the control loop With this...

Page 38: ...tting of 1 00 the analogue output 0 5V provides the nominal voltage at nominal tension force By decreasing the scale parameter the nominal voltage is decreased if the scale parameter is increased nominal voltage is also increased Range 0 01 to 10 00 Default 1 00 Increment 0 01 Unit Scaling instrument B CMGZ421 Purpose With a setting of 1 00 the analogue output 0 5V provides the nominal voltage at ...

Page 39: ...put 1 output 1 Max A B and the offset value at min 10V 20mA 13 2 Trouble shooting CMGZ421 Error Cause Corrective action Err1 A D converter channel A Channel A is wrongly connected gets signals 9 7mV change pins z6 z8 resp 2 3 Err2 A D converter channel A Channel A is wrongly connected gets signals 9 7mV supply and signal changed Short circuit in sensor connector or sensor cable Sensor overloaded S...

Page 40: ...r without line speed overlay FC AC drives DC drives with or without line speed overlay Dig output 1 open collector galv insul Controller ok Controller ok Dig output 2 open collector galv insul Controller error Controller error Dig output 3 open collector galv insul Minimum Maximum limit Minimum Maximum limit Dig output 4 open collector galv insul Minimum Maximum limit Minimum Maximum limit Dig inp...

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