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Table of Contents
Summary of Contents for ZF ERM
- Page 1 Operating instructions ZF Electronic Control Unit ERM 6057 758 101b...
- Page 2 Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documen- tation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted. Printed in Germany ZF Friedrichshafen AG, MC-C / 2001-03 Issue: 2005-02...
- Page 3 This is used when incorrect, unprofessional working practices could damage the product. Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.
- Page 4 General Information Read this manual carefully before starting any tests or repair work. CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures. Pictures, drawings and components are not to scale. Conclusions about size and weight should not be drawn (even within a complete illustration).
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Page 5: Table Of Contents
Table of contents Technical data ......Operating mode “controlled with Ø calculation” 30 Technical data, installation dimensions ..3.4.1 Function diagram . -
Page 6: Technical Data
Technical Data Electronic control unit ERM Technical data 1.1 Technical data, installation dimensions Nominal direct voltage for ZF hysteresis clutches and brakes at Ambient temperature: 0 to + 50 °C nominal torque and a coil temperature of 120 °C: 30 V DC Storage temperature: -30 to + 70 °C... - Page 7 Electronic control unit ERM Technical Data Installation dimensions 182.5 015242 6057 758 101 - 2005-02...
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Page 8: Circuit Board Removal And Installation
Technical Data Electronic control unit ERM Installation: 1.2 Circuit board removal and installation 1. Carefully insert board into rack, guiding slot without tilting. Removal: 1. Switch off operating voltage. 2. Tighten screws (1 + 4) so that the cooling attachment... - Page 9 Electronic control unit ERM Technical Data 015239 6057 758 101 - 2005-02...
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Page 10: Circuit Board Configuration
1.3 Circuit board configuration Designation Function LED (1) “Power” Supply voltage is applied and ERM program is ready. LED (2) “Feedb.” Closed-loop control operating mode, i.e. DIL switch position 5 and 6 = “1”. LED (3) • Ø sensing operation, DIL switch position 5 = “1” and 6 = “0” or “Ø-Contr.”... - Page 11 Electronic control unit ERM Technical Data Program memory DIL switches Cooling attachement Fuse 1 2 3 4 5 6 7 8 OPEN 017182 Connection for diagnostic unit Microprocessor Jumper Terminal strip Data memory E PROM 6057 758 101 - 2005-02...
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Page 12: Pin Assignment
Technical Data Electronic control unit ERM 1.4 Pin assignment +24 V to +36 V Stop 1 2 3 4 5 6 7 8 OPEN Soll Jumper 015241 Alternative function Example for external Web tear recognition – analog input, e.g. SPS... - Page 13 Electronic control unit ERM Technical Data NOTE The electronic control unit does not require the potentiometer to fulfill any particular requirements. However, mechanical require- ments regarding installation need to be considered. Recommendations for potentiometer: Resistance value: 1 kΩ - 47 kΩ...
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Page 14: Summary Of Pin Assignment
Technical Data Electronic control unit ERM Summary of pin assignment Function Function voltage input, nominal value (0 to +10 V) ground (–) input resistance R = 200 kΩ ; ground (–) Input may also be supplied by external analog sources, provided the voltage refers to ground no assignment (PIN 5) and the max. - Page 15 Electronic control unit ERM Technical Data PIN Function PIN Function frequency input - f (feedrate) current output clutch / brake frequency 3 to 1000 Hz; max. 2.55 A (depending on unit size) input resistance 3.3 kΩ NOTE: Limit for EBU 2000! pulse ≥...
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Page 16: Description
The ERM is controlled by a microprocessor and features programming, operation and diagnosis interfaces. Operating mode “open-loop control (torque)” The ERM is designed for optimum supply of the ZF 1 2 3 4 5 6 7 8 DIL switch hysteresis clutches EKU and the ZF hysteresis brakes Y Y Y Y 0 0 . - Page 17 It can therefore be used If a frequency < 3 Hz is already reached during a setting when the ERM is fitted, i.e. it can be stored in E PROM. procedure, no reference values will be transferred (LED 3 The stored reference value is deleted when another opera- continues flashing).
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Page 18: Coding Clutch / Brake
EBU 1000/100G 90.0 NOTE 0 1 1 1 EBU 2000/300G 260.0 With DIL switches 1- 4, the ERM control unit can be set to 0 1 1 1 EBU 2000/600G 520.0 the corresponding clutch or brake. 6057 758 101 - 2005-02... -
Page 19: Controller For Transfer Function
Electronic control unit ERM Description 2.3 Controller for transfer function PD for position control Coding DIL switch 1 2 3 4 5 6 7 8 PI for force control Coding e.g. mech. compensator DIL switch 1 2 3 4 5 6 7 8... -
Page 20: Operating Modes
Operating modes Electronic control unit ERM Operating modes 3.1 Operating mode “open-loop (current)” 3.1.1 Function diagram ZF Hysteresis brake Nominal traction 2.55 A Roller 015236 015234 Nominal 10 V traction 6057 758 101 - 2005-02... -
Page 21: Pin Assignment
Electronic control unit ERM Operating modes 3.1.2 Pin assignment Designation PIN connection Voltage supply plus 24 - 36 V 17, 18 Voltage supply ground 1, 2 Nominal traction sensor 7, 5, grinder 9 Hysteresis brake 16, 6 +24 to +36 V... -
Page 22: Technical Instructions
Jumper position: Jumper position “2” (see 1.4, page 13) 4. Switch off operating voltage ! can activate further functions. 5. Connect the ERM ! 6. Switch on operating voltage ! “Power” LED must light up. 7. The installation is ready for operation. -
Page 23: Operating Mode "Open Loop (Torque)
Electronic control unit ERM Operating modes 3.2 Operating mode “open-loop control (torque)” 3.2.1 Function diagram ZF Hysteresis brake Nominal traction Roller 015243 Nominal traction 6057 758 101 - 2005-02... -
Page 24: Pin Assignment
Operating modes Electronic control unit ERM 3.2.2 Pin assignment Designation PIN connection Voltage supply plus 24 - 36 V 17, 18 Voltage supply ground 1, 2 Nominal traction sensor 7, 5, grinder 9 Hysteresis brake 16, 6 +24 to +36 V... -
Page 25: Technical Instructions
0 0 0 0 DIL switch setting 4. Switch off operating voltage ! Jumper position: Jumper position “2” (see 1.4, page 13) 5. Connect the ERM ! can activate further functions. 6. Switch on operating voltage ! “Power” LED must light up. -
Page 26: Operating Mode "Controlled With Ø Sensing
Operating modes Electronic control unit ERM 3.3 Operating mode “controlled with Ø sensing” 3.3.1 Function diagram U-Ø ZF Hysteresis brake -¯ actual Ø 015236 ¯-Ist Sensor zero position equals 0 V (as shown by the broken line) Roller 015233 Nominal Ø... -
Page 27: Pin Assignment
Electronic control unit ERM Operating modes 3.3.2 Pin assignment Designation PIN connection Voltage supply plus 24 - 36 V 17, 18 Voltage supply ground 1, 2 Ø actual sensor 7, 5, grinder 8 Nominal traction sensor 7, 5, grinder 9... -
Page 28: Technical Instructions
1 0 0 0 4. Switch off operating voltage ! Jumper position: Jumper position “2” and “3” (see 1.4, 5. Connect the ERM ! page 13) can activate further functions. 6. Switch on operating voltage “Power” LED must light up. - Page 29 Electronic control unit ERM Operating modes 7. Setting of Ø nom. value potentiometer 8. Set max. roller Ø. • Voltage values U and U measured at random potentiometer setting. 9. Push “set” key. • Nom. voltage U is calculated. D a nominal 10.
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Page 30: Operating Mode "Controlled With Ø Calculation
Operating modes Electronic control unit ERM 3.4 Operating mode “controlled with Ø calculation” 3.4.1 Function diagram ZF Hysteresis brake Roller 015237 Ø Calc. value Nominal 017181 traction 6057 758 101 - 2005-02... -
Page 31: Pin Assignment
Electronic control unit ERM Operating modes 3.4.2 Pin assignment Designation PIN connection Voltage supply plus 24 - 36 V 17, 18 Voltage supply ground 1, 2 Nominal traction sensor 7, 5, grinder 9 Friction factor 7, 5, grinder 8 Roller speed... -
Page 32: Technical Instructions
The friction factor is the result of the ERM offers output signals for roller and relation between friction torque and feed stoppage (f < 3 Hz), which are nominal torque and is expressed as... -
Page 33: Startup
2.5 sec 4. Switch off operating voltage ! 1.5 sec 0.2 sec 5. Connect the ERM ! DIL switches 6. Switch on operating voltage ! 1 2 3 4 5 6 7 8 “Power” LED must light up. Filter constant “Ø... -
Page 34: Operating Mode "Closed-Loop Control
Operating modes Electronic control unit ERM 3.5 Operating mode “closed-loop control” 3.5.1 Function diagram Weight force Spring Roller Actual traction ZF Hysteresis brake Nominal 015231 015230 traction 6057 758 101 - 2005-02... -
Page 35: Pin Assignment
Electronic control unit ERM Operating modes 3.5.2 Pin assignment Designation PIN connection Voltage supply plus 24 - 36 V 17, 18 Voltage supply ground 1, 2 Actual traction sensor 7, 5, grinder 8 Nominal traction sensor 7, 5, grinder 9... -
Page 36: Technical Instructions
1 2 3 4 5 6 7 8 4. Switch off operating voltage ! Operating mode “closed-loop control” Unit size coding clutch / brake, 5. Connect the ERM ! see page 18 Controller transfer function, see page 19 6. Switch on operating voltage ! “Power”... -
Page 37: Additional Functions Max-Power / Zero-Power
• Max-power e.g. for emergency stop • Zero-power e.g. for start-up Activation of additional functions Jumper on ERM board must be in Pos. 2. Pos. 1 must not be connected! (cf. 1.4 Jumper position). • Input for max-power function: Pin 15 •... -
Page 38: Identification And Causes Of Failure / Corrective Action
Failure identification Electronic control unit ERM Identification and causes of failure / corrective action Failure identification Causes Corrective action ➢ Repeat setting procedure LED Ø contr. flashes (operating mode “controlled (see page 28) with Ø sensing”) ➢ Repeat setting procedure LED Ø...