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FMS CMGZ433 Series Operating Manual

Digital microprocessor controlled tension control unit for drives on winding applications
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Operating Manual CMGZ433
Digital microprocessor controlled tension control unit
for drives on winding applications
Version 2.22 05/04 sd
This operation manual is also available in german and french.
Please contact your local representative.
Diese Bedienungsanleitung ist auch in deutsch und französisch erhältlich.
Bitte kontaktieren Sie die Vertretung im zuständigen Land.
Ce mode d'emploi est également disponible en français et en allemand.
Veuillez contacter la représentation locale.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

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Summary of Contents for FMS CMGZ433 Series

  • Page 1 Diese Bedienungsanleitung ist auch in deutsch und französisch erhältlich. Bitte kontaktieren Sie die Vertretung im zuständigen Land. Ce mode d'emploi est également disponible en français et en allemand. Veuillez contacter la représentation locale. © by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

  • Page 2: Safety Instructions

    Operating Manual CMGZ433 1 Safety Instructions 1.1 Description conditions a) High danger of health injury or loss of life Danger This symbol refers to high risk for persons to get health injury or loss life. It has to be followed strictly. b) Risk of damage of machines Caution This symbol refers to informations, that, if ignored, could cause heavy mecanical damage.

  • Page 3: Table Of Contents

    Operating Manual CMGZ433 Table of contents 1 Safety Instructions.................... 2 1.1 Description conditions 1.2 List of safety instructions 2 Definitions ......................4 3 System components ..................4 4 System description.................... 5 4.1 Functional description 4.2 Force sensors 4.3 Electronic unit CMGZ433 4.4 Drive 5 Controller theory....................

  • Page 4: Definitions

    (0...10V). Strain gauge: Electronic component that will change its resistance while its length has changed. Strain gauges are used in the FMS force sensors for acquisition of the feedback value.

  • Page 5: System Description

    Operating Manual CMGZ433 4 System description fig. 1: Basic structure of a drive control system on an winding application C433003e 4.1 Functional description The force sensors measure the tension force in the material and transmit the measuring value as a mV signal to the electronic unit CMGZ433. The electronic unit amplifies the mV signal and calculates the error to the reference value.

  • Page 6: Drive

    Operating Manual CMGZ433 Controller The control unit compares the reference value with the measured feedback value and transmits the error to the controller configurable as PI or PID. The controller calculates the output signal according to the difference. The output signal is provided as an analog signal (0...10V / ±10V / 0...20mA / 4...20mA).

  • Page 7: Controller Theory

    Tension may change when humidity, temperature, winding or unwinding diameters vary or when the sheets are being printed, coated, glued or pressed. Tension is measured constantly and maintained at the correct value with the FMS force measuring and control system.

  • Page 8: Quick Installation Guide

    Operating Manual CMGZ433 6 Quick installation guide • Check all your requirements such as: – Charateristics of the drive (signal level, max. power, etc.)? – Controller output configuration (signal level)? – Feedback output configuration (signal level)? – Gain switching required? –...

  • Page 9: Dimensions

    Operating Manual CMGZ433 7 Dimensions 7.1 Dimensions: Variant for insert card support block (CMGZ433) fig. 4: Dimensions of the variant using insert card support block (series CMGZ400). The support block EMGZ555959 has to be ordered separately. C431006us If the electronic unit should be mounted into a 19“ rack, a multipoint plug is used instead of the support block.

  • Page 10: Installation And Wiring

    Operating Manual CMGZ433 8 Installation and wiring Caution Proper function of the Tension Controller is only guaranteed with the recommended application of the components. In case of other arrangement, heavy malfunction can be the result. Therefore, the installation instructions on the following pages must be followed strictly.

  • Page 11: Mounting The Force Sensors

    Operating Manual CMGZ433 8.2 Mounting the force sensors Mounting of the force sensors is done referring to the FMS Installation manual which is delivered together with the force sensors. Wiring to the terminals of the electronic unit is done according to wiring diagram (fig. 6 resp.

  • Page 12: Wiring Diagram: Variant For Insert Card Support Block (Cmgz433)

    Operating Manual CMGZ433 8.4 Wiring diagram: Variant for insert card support block (CMGZ433) fig. 6: Wiring diagram: Variant for insert card suppor block C433006e 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.
  • Page 13 Operating Manual CMGZ433 fig. 7: Wiring diagram: Variant with separate housing C433009e fig. 8: Screw terminal arrangement on Terminal board C432007e...

  • Page 14: Mounting The Distance Sensor

    (refer to fig. 1 and 9). Optical distance sensor CMGZ581934 FMS recommends to use the optical distance sensor CMGZ581934 because its accuracy and signal output is adapted to the FMS measuring amplifiers and Tension Controllers. fig. 9: Mounting of the distance sensor CMGZ581924 E411012e The distance sensor operates with the 3-beam-correction principle.

  • Page 15: Operation

    Operating Manual CMGZ433 9 Operation 9.1 View of the operating panel fig. 10: Operating panel: Variant for insert card support block (CMGZ433) C433001e fig. 11: Operating panel: Variant with separate housing (CMGZ433.E) C433002e...

  • Page 16: Schematic Diagram Of Main Operating Menu

    Operating Manual CMGZ433 9.2 Schematic diagram of main operating menu fig. 12 C432010e 9.3 Checking the parameters Before the initial setup is done, the following parameters have to be set resp. you have to check if they correspond with the effective machine conditions (ref. to „11. Parametrization“): Measuring amplifier parameters •...

  • Page 17: Calibrating The Measuring Amplifier

    Operating Manual CMGZ433 9.4 Calibrating the measuring amplifier Simulating Method (recommended) The following instructions are referring to a setup and calibration on-site. The material tension will be simulated by a weight (fig. 13). • Connect the first force sensor • Check, if a positive value is displayed when loading the sensor in measuring direction.
  • Page 18 • Offset adjustment has to be done as described under „Simulating method“. • The Gain value will be calculated by the following formula and then inputted in the parameter gain feedback (refer to „11. Parametrization“). fig. 14: Force vectors in the FMS force measuring bearing C431012e GainFeedback δ...

  • Page 19: Inputting The Reference Value

    Operating Manual CMGZ433 9.5 Inputting the reference value The material tension reference value can be inputted by the operating panel resp. interface, or by the analog input: reference input by operating panel resp. interface • Set parameter reference internal / external to internal •...

  • Page 20: Switching The Control Parameters

    Operating Manual CMGZ433 Mathematic determination of control parameters • If the behaviour of the control loop is known, the control parameters may be calculated by the known mathematical procedures and saved in the parameters Proportional P0...P3, Integral I0...I3 resp. Derivative D0...D3. (There is only the parameter set active which is chosen by the BCD inputs;...

  • Page 21: Automatic Operation

    Operating Manual CMGZ433 9.8 Automatic operation State „Controller disabled“ After power on, the controller is disabled. Its output value is 0V, 0mA or 4mA (depending on setting of parameter Output config.) Enable controller The controller will be enabled by digital input „Controller enabled“ or by serial interface. The controller then begins to tighten the material with the speed given by parameter Start speed until an initial material tension (parameter Start limit) is reached.

  • Page 22: Setup Of External Pilot Control

    Operating Manual CMGZ433 9.9 Setup of external pilot control The external pilot control enables to evaluate the actual reel diameter (diameter signal is read from external source) and to calculate a drive output adapted to the reel diameter (pilot control signal). In addition, the PI resp. PID control parameters are dynamically adapted to the reel diameter continuously.
  • Page 23 Operating Manual CMGZ433 Adjustment of pilot control To get the electronic unit calculating the pilot control correct, a certain drive torque has to be assigned to a certain diameter: • Set parameter Pilot control to No • Proceed for a test run. If the control loop runs stable at a diameter as large as possible, the actual reference value and, after pressing the „Mode“...

  • Page 24: Setup Of Internal Pilot Control

    The internal pilot control is only suitable with a speed controlled drive.Using a torque controlled drive the external pilot control has to be used. (To be developped – ask FMS customer service) 9.11 Tension reduction If the end of the reel should be wound smoother than the center of the reel, a tension reduction can be parametrized.

  • Page 25: Additional Settings

    9.12 Additional settings PI or PID configuration The Tension Controller can be operated as PI or as PID controller. FMS recommends operating as PI controller because this setup is much easier to handle, and the controller dynamics are sufficient for most applications (refer also to „5. Controller theory“):...

  • Page 26: Serial Interface (Rs232)

    Operating Manual CMGZ433 10 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. If the answer is missing, the electronic unit or the connection cable may fail.

  • Page 27: Command List

    Operating Manual CMGZ433 10.2 Command list command answer purpose DAKT<CR> XXXXXX<CR> read actual diameter DIFF<CR> DIFY<CR> / DIFN<CR> read alarm control error DIFR<CR> DIFRXXXX.X<CR> actual control error in % ERR?<CR> XX<CR> read actual erros Pos.1...2 : Err1...Err2 Value of Pos. = 0 : No Err; Value of Pos.

  • Page 28: Write Parameter

    Operating Manual CMGZ433 RP15<CR> X<CR> display language RP16<CR> X<CR> pilot control RP17<CR> XXX.X<CR> influence of PID RP18<CR> X<CR> PID-configuration RP19<CR> XXX.XX<CR> proportional P0 RP20<CR> XXX.XX<CR> integral I0 RP21<CR> XX.XXX<CR> derivative D0 RP22<CR> XXX.XX<CR> proportional P1 RP23<CR> XXX.XX<CR> integral I1 RP24<CR> XX.XXX<CR>...
  • Page 29 Operating Manual CMGZ433 WP13X<CR> PACC<CR> / FAIL<CR> limit 2 min / max WP14XXXXX<CR> PACC<CR> / FAIL<CR> limit value 2 WP15X<CR> PACC<CR> / FAIL<CR> display language WP16X<CR> PACC<CR> / FAIL<CR> pilot control WP17XXX.X<CR> PACC<CR> / FAIL<CR> influence of PID WP18X<CR> PACC<CR> / FAIL<CR> PID-configuration WP19XXX.XX<CR>...

  • Page 30: Parametrization

    Operating Manual CMGZ433 11 Parametrization 11.1 Parameter list Parameter Unit Default Actual Find offset (Parameter function) Calibration feedback (Parameter function) _______ Auto. diameter adjust (Parameter function) Adjustm. of pilot control (Parameter function) Offset feedback [Digit] -4000 4000 _______ Gain feedback 1.000 0.100 9.000...

  • Page 31: Schematic Diagram Of Parametrization

    Operating Manual CMGZ433 Output configuration ±10V, 0...10V, 0...20mA, 4...20mA _______ Ramp diameter 60.0 _______ Ramp reference 20.0 _______ Reference Internal, External Internal _______ Scale ref. input [N,kN] 9999 _______ Tension reduction No, Linear, Square, Root _______ Reduction factor 0.000 0.000 1.000 _______ Start speed...

  • Page 32: Description Of The Parameters

    Operating Manual CMGZ433 11.3 Description of the parameters The parameter changing mode will be activated by pressing the ↵ key for 3 seconds. Generally, the parameters are settable using the keys as follows: ↵ choose ↑ ↓ switch the selections or increase / decrease numeric values ←...
  • Page 33 Use: To get the correct force value,, the electronic unit has to know the sensitivity of the force sensors, that means how much signal the sensor will answer by nominal force. Standard for FMS force sensors is 1.8mV/V. Range: Default:...
  • Page 34 Operating Manual CMGZ433 1 or 2 sensors Use: To get the correct force value, the electronic unit has to know if the measuring roller is beared by one or two force sensors. Range: Default: Increment: Unit: Lowpass output Use: The electronic unit provides a lowpass filter to prevent noise which is added to the feedback signal, caused by unbalanced rollers or interference.
  • Page 35 Operating Manual CMGZ433 Scale instrument Use: The analog output for the external instrument (0...10V) provides the nominal voltage when reaching the nominal force value. Using a setting of 1.00, the nominal voltage will be 10V. The nominal voltage is decreased when decreasing the setting value; it is increased when increasing the setting value.
  • Page 36 Operating Manual CMGZ433 Pilot control Use: With this parameter, the operation mode of the pilot control is set. Range: No, Internal, External Default: Definition: No pilot control. Internal: The line speed signal is evaluated; the reel diameter is calculated internally. External: The diameter signal is evaluated;...
  • Page 37 Operating Manual CMGZ433 Integral I0 Use: This value determines the behaviour of the „I“ component of the controller. It is active if the BCD inputs are set to „0“. If the value stored here is 1.00 the I controller will produce an output signal changement of 1V/s resp.
  • Page 38 „±10V“, the drive unit can run and brake both in forward and reverse direction. With the other settings, the drive unit can only run and brake in forward direction. FMS recommends setting to „±10V“ if the used drive unit supports this signal. Range: ±10V, 0...10V, 0...20mA, 4...20mA...
  • Page 39 Operating Manual CMGZ433 Scale reference input Use: This parameter defines how many N resp. kN are assigned to the 0...10 V signal on the analog input. If no 10V signal is available, you can use a signal with any tension range, but you must scale the entry in this parameter corresponding to the tension range.
  • Page 40 100.0 Default: Increment: Unit: [%F_ref] Leading drive Use: This parameter is used to calculate the reel diameter from the line speed signal. (To be developed – ask FMS customer service) Range: 1000 Default: Increment: Unit: [rpm/V] Controlled drive Use: This parameter is used to calculate the reel diameter from the line speed signal.
  • Page 41 Operating Manual CMGZ433 Max. diameter Use: This parameter stores the diameter of the fully winded reel (Dmax). It is used for tension reduction. Range: 10000 Default: 1000 Increment: Unit: [mm] Identifier Use: This parameter is to identificate the device when using a CAN-Bus interface.

  • Page 42: Trouble Shooting

    No message on the on the processor board on the upper right edge display beside the ribbon connector) Fuse blown Replace fuse on power supply Power supply not correct Check / correct power supply Electronic unit defect Contact FMS customer service...

  • Page 43: Technical Data Cmgz433

    Operating Manual CMGZ433 13 Technical data CMGZ433 Connection of force sensors 1 or 2 parallel force sensors of 350Ω Excitation of sensors 4VDC Input signal voltage 9.9mV Resolution A/D-converter ±4095 Digit (13 Bit) Measuring error <0.05% FS Cycle time Operation 4 keys, LCD display 2x16 characters, 4 LED Setting of reference value Alternatively: Operating panel...
  • Page 44 Operating Manual CMGZ433 FMS Force Measuring Systems AG FMS Italy FMS USA, Inc. FMS UK Aspstrasse 6 Via Baranzate 67 2155 Stonington Ave. Suite 119 Highfield, Atch Lench Road 8154 Oberglatt (Switzerland) I-20026 Novate Milanese Hoffman Estates, IL 60169 USA Church Lench Tel.
  • Page 45 Operating Manual CMGZ433...

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