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FMS CMGZ 622 Operating Manual

Digital tension controller for double range force sensors
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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.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

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Summary of Contents for FMS CMGZ 622

  • Page 1 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. © by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

  • Page 2: Table Of Contents

    Operating Manual CMGZ 622 Table of Contents Safety Instructions ..................4 Description conditions List of safety instructions Definitions ....................5 System Components .................. 6 System Description..................7 Functional Description Force Sensors Electronic Unit CMGZ622 Power Amplifier and Brake Drive and Motor Controller theory..................
  • Page 3 Operating Manual CMGZ 622 12.4 Taper Function Setup of a Line Drive Controller ............34 13.1 Configuring the basic parameters 13.2 Setup of line speed overlay Parametrization..................36 14.1 Schematic Diagram of Parametrization 14.2 List of System Parameters 14.3 List of Parameters CMGZ622 14.4...

  • Page 4: Safety Instructions

    Operating Manual CMGZ 622 1 Safety Instructions 1.1 Description conditions High danger of health Risk of damage Notice for injury or loss of life to machines proper function Note Caution Danger This symbol refers to an This symbol refers to risk...

  • Page 5: Definitions

    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 6: System Components

    Operating Manual CMGZ 622 3 System Components A CMGZ622 tension control system consists of the following components (refer to fig. 1): Force sensors • Double range force measuring bearings • For mechanical/electrical conversion of the tension force Electronic unit CMGZ622 •...

  • Page 7: System Description

    Operating Manual CMGZ 622 4 System Description fig. 1: Basic structures of the CMGZ622 configurations C622001e 4.1 Functional Description The double range force sensors measure the tension force in the material and transmit the measuring values as mV signals to the electronic unit CMGZ622. The electronic unit amplifies the mV signal depending on configuration.

  • Page 8: Electronic Unit Cmgz622

    Operating Manual CMGZ 622 4.3 Electronic Unit CMGZ622 Common The electronic unit is mounted to a robust aluminium housing. It contains a microprocessor to handle all calculations and communications, the highly accurate sensor power supply and the signal amplifiers for the measuring values of a measuring point.

  • Page 9: Power Amplifier And Brake

    Operating Manual CMGZ 622 fig. 2: Block diagram of the electronic unit CMGZ622 C622002e 4.4 Power Amplifier and Brake (Only if a brake is operated) The electronic unit can be ordered with integrated brake amplifier CMGZ.B. If the electronic unit was ordered without brake amplifier, a separate power amplifier has to be used.

  • Page 10: 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 11: Quick Installation Guide

    Operating Manual CMGZ 622 6 Quick Installation Guide • Check all your requirements such as: – operating mode (unwind brake, unwind drive, winding drive, line drive)? – characteristics of the brake or drive (signal level, max. current, etc.)? – configuration of the force sensor (power supply, 4 wire or 6 wire circuit)? –...

  • Page 12: Dimensions

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

  • Page 13: Installation And Wiring

    Operating Manual CMGZ 622 8 Installation and Wiring Caution Proper function of the electronic unit 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 14 Operating Manual CMGZ 622 Caution The processor board is mounted to the housing cover. Improper handling may damage the fragile electronic 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.

  • Page 15: Wiring Diagram Cmgz622

    Operating Manual CMGZ 622 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: Mounting The Force Sensors

    Operating Manual CMGZ 622 8.3 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. The connection between the force sensors and the electronic unit is done using 4x2x0.75mm [AWG 18] shielded twisted pair cable.

  • Page 17: Mounting The Distance Sensor

    (refer to fig. 1 and 10). Optical distance sensor CMGZ581934 FMS recommends to use the optical distance sensor CMGZ581934 because its accuracy and signal output is adapted to the FMS Tension Measuring Amplifiers and Tension Controllers. fig. 10: Mounting of the distance sensor CMGZ581924 E411012e The distance sensor operates with the 3-beam-correction principle.

  • Page 18: General Operation

    Operating Manual CMGZ 622 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 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 (default) 1 or 2 sensors 1 or 2 per channel Lowpass feedback Reset to default = 50.0 Hz Scale instrument 1 Which material tension feedback refers to 10V resp.

  • Page 20: Calibrating The Measuring Amplifier

    Operating Manual CMGZ 622 9.2 Calibrating the Measuring Amplifier The calibration can be done using the „simulating method“ or the „mathematical method“: 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.
  • Page 21 • Offset adjustment is done as written under „Simulating method“. • The Gain 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 bearing C431012e GainFeedba δ...

  • Page 22: Setup The Pid Controller

    Operating Manual CMGZ 622 9.3 Setup the PID Controller The setup of the PID controller section depends on the operating mode of your application. Thus refer to „10. Setup of an Unwind Brake Controller“ / „11. Setup of an Unwind Drive Controller“ / „12. Setup of a Winding Drive Controller“ / „13. Setup of a Line Drive Controller“.

  • Page 23: Switching The Control Parameters

    Operating Manual CMGZ 622 • If the Derivative D is too high, the control loop will become unstable again. • If the control loop is running stable, the parameters Proportional P, Integral I and Derivative D should be noted for eventually re-setup.

  • Page 24: Automatic Operation

    Operating Manual CMGZ 622 Switching is done by using the digital inputs „switch range“ and „switch PID“ (ref. to wiring diagram) according to the table below: Measuring Range dig. input dig. input Parameter set switch range switch PID Range 1...

  • Page 25: Additional Settings

    The Tension Controller can be operated as PI or as PID controller (with unwind brake, PI only). 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.
  • Page 26 Operating Manual CMGZ 622 Setting of the limit switches The electronic unit provides 2 limit switches which can be tapped at the digital outputs. The limit switches are actuated when the feedback value exceeds the stored threshold values. For details see description of parameters Limit 1 min/max, Limit value 1, Limit 2 min/max, Limit value 2 (ref.

  • Page 27: Setup Of An Unwind Brake Controller

    Operating Manual CMGZ 622 10 Setup of an Unwind Brake Controller 10.1 Configuring the basic parameters For an unwind brake controller the following parameters must be set according to your application: Parameters CMGZ622 Control mode Unwind brake (default) Pilot control...

  • Page 28: Setup Of Pilot Control

    Operating Manual CMGZ 622 10.3 Setup of pilot control The pilot control enables to evaluate the actual reel diameter and to calculate the brake torque or drive power adapted to the reel diameter (pilot control signal). In addition, the PID control parameters are dynamically adapted to the reel diameter continuously.
  • Page 29 Operating Manual CMGZ 622 • Insert reel with large diameter to get a signal according to the large diameter from the distance sensor, or set PLC diameter signal to a large value. • Input the actual (large) reel diameter as Diameter 2 as written above (fig. 16).
  • Page 30 Operating Manual CMGZ 622 fig. 17: Program flow for special function „Adjust pilot control“ C611008e Note The additional analog input can only be operated in one mode at a time. When changing parameter Reference source, Pilot control or Taper function, the...

  • Page 31: Setup Of An Unwind Drive Controller

    Operating Manual CMGZ 622 11 Setup of an Unwind Drive Controller 11.1 Configuring the basic parameters For an unwind drive controller the following parameters must be set according to your application: Parameters CMGZ622 Unwind drive Control mode Pilot control For the time being set to No PID configuration For the time being set to PI;...

  • Page 32: Setup Of A Winding Drive Controller

    Operating Manual CMGZ 622 12 Setup of a Winding Drive Controller 12.1 Configuring the basic parameters For a winding drive controller the following parameters must be set according to your application: Parameters CMGZ622 Winding drive Control mode Pilot control For the time being set to No PID configuration For the time being set to PI;...

  • Page 33: Setup Of Pilot Control

    The characteristic curve can be chosen as a linear, square or square root function (fig. 18). But the taper function is only active if the pilot control is also active, that means the controller must know the actual reel diameter. (to be developed – ask FMS customer service)

  • Page 34: Setup Of A Line Drive Controller

    Operating Manual CMGZ 622 13 Setup of a Line Drive Controller 13.1 Configuring the basic parameters For a line drive controller the following parameters must be set according to your application: Parameters CMGZ622 Line drive Control mode Line speed overlay...
  • Page 35 Operating Manual CMGZ 622 Parametrization of the tachometer roller For the controller knowing the actual line speed, the line speed signal has to be set in relation to the diameter and speed of the tachometer roller: • Set line speed signal on the master computer or on a drive already setup to a certain value, for ex.

  • Page 36: Schematic Diagram Of Parametrization

    Operating Manual CMGZ 622 14 Parametrization 14.1 Schematic Diagram of Parametrization fig. 19: Parametrization CMGZ612 C612003e The parameters are split into the modules Params System 0 and Params CMGZ622 1. The parameter changing mode is activated by pressing the PARA ↵ key for 3 seconds.

  • Page 37: List Of System Parameters

    Operating Manual CMGZ 622 14.2 List of System Parameters Parameter Unit Default Language English, French, Italian, German Measuring System Metric, US standard Metric Lowpass display [Hz] 10.0 Identifier Baud rate 2400, 4800, 9600, 19200 9600 14.3 List of Parameters CMGZ622...
  • Page 38 Operating Manual CMGZ 622 Code refers to: b = unwind brake / u = unwind drive / w = winding drive / l = line drive [N, cN, kN] if measuring system = metric / [lb, clb, klb] if measuring system = US standard A force value can be input.
  • Page 39 Operating Manual CMGZ 622 Parameter Applies to Unit Default _ _ _ l Tacho voltage [rpm/V] 1000 _ _ _ l Controlled drive [rpm/V] 1000 _ _ _ l Tacho diameter _ _ w l Center diameter _ _ w _ Max.

  • Page 40: Description Of The System Parameters

    Operating Manual CMGZ 622 14.4 Description of the System Parameters The parameter changing mode is activated by pressing the PARA ↵ key for 3 seconds. By pressing the PARA ↵ key again, the system parameters are selected (ref. also to fig.

  • Page 41: Description Of The Parameters Cmgz622

    Operating Manual CMGZ 622 14.5 Description of the Parameters CMGZ622 The parameter changing mode is activated by pressing the PARA ↵ key for 3 seconds. The module Params CMGZ622 1 is then searched with the ↑ ↓ keys and selected with the PARA ↵...
  • Page 42 Operating Manual CMGZ 622 Gain feedback 1 Applies to: Unwind brake Unwind drive Winding drive Line drive Use: This parameter stores the value wasdetermined with special function Calibration while the digital input „switch range“ was OFF (measuring range 1). Alternatively you can input a value calculated using the formulas written under „9.3 Calibrating the measuring...
  • Page 43 Line drive Use: This parameter stores the sensitivity of the force sensor, that means how much signal per volt excitation the sensor will give when loaded with nominal force. Standard for FMS force sensors is 1.8mV/V. Range: 0.1 to Default:...
  • Page 44 Operating Manual CMGZ 622 Limit value 1 Applies to: Unwind brake Unwind drive Winding drive Line drive Use: The digital output „Limit value 1“ will be activated if the threshold value stored in this parameter is passed over respectively passed under (according to setting in parameter Limit 1 min / max).
  • Page 45 Operating Manual CMGZ 622 Scale instrument 2 Applies to: Unwind brake Unwind drive Winding drive Line drive Use: This parameter stores which material tension feedback value will give the maximum signal (10V and 20mA) at the output if measuring range 2 is used (digital input „switch range“ = ON).
  • Page 46 Operating Manual CMGZ 622 PID-configuration Applies to: Unwind drive Winding drive Line drive Use: This parameter determines if the controller is operated as a PI or as a PID controller. If it is operated as a PI controller, the parameters Derivative D1...D4 are ineffective.
  • Page 47 Operating Manual CMGZ 622 Derivative D1 / D2 / D3 / D4 Applies to: Unwind drive Winding drive Line drive Use: The D value determines the behaviour of the „D“ component of the controller. This parameter can be changed while the controller is enabled. The new value is taken for the control loop when quit parameter mode.
  • Page 48 Operating Manual CMGZ 622 Offset output Applies to: Unwind brake Use: If the brake is activated although the controller gives no signal to the brake, the faulty brake torque can be compensated here. The value stored here is active only if the controller is enabled.
  • Page 49 „±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. However, for a brake the other settings are preferred. Range: ±10V, 0...10V, 0...20mA, 4...20mA...
  • Page 50 Operating Manual CMGZ 622 Reference source Applies to: Unwind brake Unwind drive Winding drive Line drive Use: If the reference value will be set using the operating panel or the interface, this parameter has to be set to internal. If the reference value will be set using a 0...10V signal led to the analog input, this...
  • Page 51 Applies to: Winding drive Use: This parameter defines the shape of the characteristic curve for the taper function (ref. to „12.4 Taper function“) (To be developed – ask FMS customer service) Range: No, Linear, Square, Root Default: Reduction factor Applies to:...
  • Page 52 Operating Manual CMGZ 622 Start speed Applies to: Unwind drive Winding drive Use: If the material is hanging loosely during enabling the controller, the controller would rewind the material with maximum speed to build the needed material tension. The drive unit then cannot brake fast enough, and cracking of the material can be the result.
  • Page 53 Operating Manual CMGZ 622 Tacho diameter Applies to: Line drive Use: This parameter stores the diameter of the tacho roller. It is used for the line speed overlay function. Range: A diameter value can be input. The value consists of 4 digits.

  • Page 54: Service Mode

    Operating Manual CMGZ 622 14.6 Service Mode fig. 20: Service Mode Overview C622007e The service mode contains internally used values. These need usually no modification. However, they could be helpful while trouble shooting. Each function module has its own set of service parameters.
  • Page 55 Operating Manual CMGZ 622 Internal reference 1 / 2 / 3 / 4 Applies to: Unwind brake Unwind drive Winding drive Line drive Use: This parameter stores the internal reference value given with special function Edit ref. value. There are 4 different reference values available, depending on the control parameter set which is active.
  • Page 56 Operating Manual CMGZ 622 Pilot output Applies to: Unwind brake Unwind drive Winding drive Use: This parameter stores the required torque as a percentage of the maximum output value. The value is determined with special function Adjust pilot control. Range:...

  • Page 57: Serial Interface (Rs232)

    Operating Manual CMGZ 622 15 Serial Interface (RS232) (Optional)

  • Page 58: Profibus Hardware Interface Description

    Operating Manual CMGZ 622 16 PROFIBUS Hardware Interface Description 16.1 Wiring of the PROFIBUS Data Cable Wiring of the PROFIBUS cables The standardized PROFIBUS cable type A (STP 2x0.34 ) [AWG] has to be used for the PROFIBUS data cable. The cables are bared referring to fig. 6 and connected to the terminals according to the wiring diagramm.

  • Page 59: Profibus Interface Description

    Operating Manual CMGZ 622 17 PROFIBUS Interface Description 17.1 GSD File The PROFIBUS DP Master has to know which devices are connected to the PROFIBUS network. For this purpose the GSD file is required. The GSD file for the CMGZ600A- series tension controller can be taken fron the following internet address: http://www.fms-technology.com/gsd...

  • Page 60: Configuration

    Operating Manual CMGZ 622 17.4 Configuration The configuration defines how many process data (byte and word) are sent during the cyclic communication from the control system to the tension controller and from the tension controller to the control system. To ensure maximum flexibility using the tension controller, there are different modules supplied.

  • Page 61: Function Code

    Operating Manual CMGZ 622 17.5 Function Code Master → Slave Function Values Value Meaning Remarks Feedback feedback tension controller Reference reference tension controller Controller Error controller error tension controller Output output tension controller A/D-value brutto A/D-value tension controller The tension controller transmitt the response with the response telegram 17.6 Error Code...

  • Page 62: Interface Can-Bus

    Operating Manual CMGZ 622 18 Interface CAN-Bus (Optional)

  • Page 63: Technical Reference

    Operating Manual CMGZ 622 19 Technical Reference 19.1 Additional Setting Elements fig. 21 E600004e Element Function D111 Status LED power supply: VCC ok D114 Status LED power supply: +15VDC ok D115 Status LED power supply: –15VDC ok D408 Status LED dig. input 1 D409 Status LED dig.

  • Page 64: Setting Elements On The Extension Board

    Operating Manual CMGZ 622 19.2 Setting Elements on the Extension Board fig. 22 C600002 Element Function IN1...16 Status LED dig. input 1...16 OUT1...8 Status LED dig. output 1...8 (open collector) REL1...8 Status LED and relay dig. output 9...16 J308 / J317 Terminal for dig.

  • Page 65: Jumper For The Analogue Inputs / Outputs

    Operating Manual CMGZ 622 19.3 Jumper for the Analogue Inputs / Outputs fig. 23: The jumpers and solder bridges show the settings for processing an FMS force sensor signal. E600005e Caution Wrong setting of the jumpers and solder bridges may cause malfunction of the...
  • Page 66 Operating Manual CMGZ 622 Setting the analog output (jumper) Channel 1 Channel 2...4 Analog output Analog output (main board) (subprint) 0...10V ±10V (default) J1100 J100 Setting the sensor excitation (solder bridges) Channel 1 Channel 2...4 Sensor excitation (main board) (subprint)

  • Page 67: Technical Data

    Operating Manual CMGZ 622 19.4 Technical Data Number of measuring points Connection of force sensors 2 parallel wired double range force sensors of 2 x 350Ω for each measuring point Excitation of force sensors 5VDC (default) or 10VDC (with automatic current control) Input signal voltage 0...9mV (max.

  • Page 68: Trouble Shooting

    Operating Manual CMGZ 622 20 Trouble Shooting If the electronic unit detects an error, a digital output is activated. In addition, the error state can be read by the interface. 20.1 General Trouble shooting Error Cause Corrective action The control error has Enlarge parameter Alarm limit „Alarm control error“...
  • Page 69 Operating Manual CMGZ 622 Error Cause Corrective action effective material Sensor excitation set Check solder bridges for sensor wrong excitation of channel n (ref. to tension „19.3 Jumper for the Analog Inputs / Outputs“) Sensor signal level set Check solder bridges for sensor wrong signal of channel n (ref.

  • Page 70: Unwind Brake Trouble Shooting

    Operating Manual CMGZ 622 Error Cause Corrective action Electronic unit defect Check status LED’s of the power supply (D111...D115, ref. to „19.1 Additional Setting Elements“) Contact FMS customer service The interfacesare not Contact FMS customer service Electronic unit does not answer to...

  • Page 71: Winding Drive Trouble Shooting

    Operating Manual CMGZ 622 20.4 Winding Drive Trouble shooting Error Cause Corrective action Roller does stay or Parameter Start speed set Increase parameter Start speed too low winds too slow when enabling the controller Parameter Start limit set Decrease parameter Start limit...
  • Page 72 Operating Manual CMGZ 622 FMS Force Measuring Systems AG FMS USA, Inc. FMS (UK) FMS Italy Aspstrasse 6 2155 Stonington Avenue Suite 119 Highfield, Atch Lench Road Via Baranzate 67 8154 Oberglatt (Switzerland) Hoffman Estates,, IL 60169 (USA) Church Lench 20026 Novate Milanese Tel.

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