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FMS CMGZ432 Operating Manual

Digital microprocessor controlled tension control unit for drives on unwinding applications
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Operating Manual CMGZ432
Digital microprocessor controlled tension control unit
for drives on unwinding 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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  • 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 CMGZ432 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.

  • Page 3: Table Of Contents

    8.1 Mounting and wiring of the electronic unit 8.2 Mounting the force sensors 8.3 Mounting the drive unit 8.4 Wiring diagram: Variant for insert card support block (CMGZ432) 8.5 Wiring diagram: Variant with separate housing (CMGZ432.E) 8.6 Mounting the distance sensor 9 Operation ......................

  • 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

    The force sensors measure the tension force in the material and transmit the measuring value as a mV signal to the electronic unit CMGZ432. The electronic unit amplifies the mV signal and calculates the error to the reference value. If the material tension is too low, the drive will be driven slower;...

  • Page 6: Drive

    Interface As standard, the electronic unit supports an RS232 interface. As an option, there is an additional board with CAN-Bus interface available. fig. 2: Block diagram of the electronic unit CMGZ432 C432002e 4.4 Drive There can be used any AC or DC four-quadrant drive selected according to the required...

  • 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 CMGZ432 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 CMGZ432 7 Dimensions 7.1 Dimensions: Variant for insert card support block (CMGZ432) 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

    8.1 Mounting and wiring of the electronic unit Variant for insert card support block (CMGZ432) The insert card support block can be mounted in a control cabinet. Wiring to the terminals is done according to „8.4 Wiring diagram: Variant for insert card support block“ (fig. 6).

  • Page 11: Mounting The Force Sensors

    Operating Manual CMGZ432 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 (Cmgz432)

    Operating Manual CMGZ432 8.4 Wiring diagram: Variant for insert card support block (CMGZ432) fig. 6: Wiring diagram: Variant for insert card suppor block C432006e 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 CMGZ432 fig. 7: Wiring diagram: Variant with separate housing C432013e 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 CMGZ432 9 Operation 9.1 View of the operating panel fig. 10: Operating panel: Variant for insert card support block (CMGZ432)C432008e fig. 11: Operating panel: Variant with separate housing (CMGZ432.E) C432009e...

  • Page 16: Schematic Diagram Of Main Operating Menu

    Operating Manual CMGZ432 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.

  • Page 17: Calibrating The Measuring Amplifier

    Operating Manual CMGZ432 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 CMGZ432 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 CMGZ432 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 CMGZ432 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.

  • Page 22: Setup Of External Pilot Control

    Operating Manual CMGZ432 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 CMGZ432 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

    This will increase controlling stability. Notice 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)

  • Page 25: Additional Settings

    9.11 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 CMGZ432 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 CMGZ432 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;...

  • Page 28: Write Parameter

    Operating Manual CMGZ432 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>...
  • Page 29 Operating Manual CMGZ432 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> PACC<CR> / FAIL<CR> proportional P0 WP20XXX.XX<CR> PACC<CR> / FAIL<CR> integral I0 WP21XX.XXX<CR> PACC<CR> / FAIL<CR> derivative D0 WP22XXX.XX<CR>...

  • Page 30: Parametrization

    Operating Manual CMGZ432 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...

  • Page 31: Schematic Diagram Of Parametrization

    Operating Manual CMGZ432 Output limit 100.0 10.0 100.0 _______ 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 _______ Start speed [%Out] 0.00 0.00 100.00...

  • Page 32: Description Of The Parameters

    Operating Manual CMGZ432 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 CMGZ432 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. This parameter stores the limit frequency. The filtered feedback value will be fed to the PI controller.
  • Page 35 Operating Manual CMGZ432 Limit 1 min / max Use: The digital output „Limit value 1“ can be set as a min- or a max limit switch. That means, that the digital output will be activated when passing over resp. passing under the value set under parameter Limit value 1.
  • Page 36 Operating Manual CMGZ432 Influence of PI Use: If pilot control is activated, this parameter defines the percentage participation of the PI resp. PID controller which will be added to the pilot control signal. „10%“ means 10% of the maximum output signal.
  • Page 37 Operating Manual CMGZ432 Proportional P1 Use: Description and function see Proportional P0. Active if the BCD inputs are set to „1“. Integral I1 Use: Description and function see Integral I0. Active if the BCD inputs are set to „1“. Derivative D1 Use: Description and function see Derivative D0.
  • 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 „10“ refers to 10% of the reference value [N]. Range: 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]...
  • Page 40 Operating Manual CMGZ432 Controlled 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] Tacho diameter Use: This parameter is used to calculate the reel diameter from the line speed signal.
  • Page 41 Operating Manual CMGZ432 1 or 2 stop bit Use: Setting of the number of stop bits of the RS 232 interface. Range: Default: Increment: Unit: Parity bit RS232 Use: Setting of the paroty of the RS 232 interface. Range: none, odd, even...

  • Page 42: Trouble Shooting

    Operating Manual CMGZ432 12 Trouble shooting Error Cause Corrective action Force sensors are wrong Exchange wires on terminals z6 / z8 (resp. 2 / 3) „Err1“ is displayed: A/D-converter receives connected values < -9.7mV continuously Parting of the cable Replace connection cable between force sensor...

  • Page 43: Technical Data Cmgz432

    Digital input 4 (BCD cipher 1) 24VDC galvanic separated Interface RS232 standard Interface RS485 galvanic separated Option Interface CAN-Bus Option Power supply 24VDC (18...36VDC) 0.15A (CMGZ432.E: 230VAC, 110VAC or 24VDC) Main connector DIN41612 version F b+d+z Temperature range 0...50°C [32...122°F] Weight 0.22kg [0.5lbs]...
  • Page 44 Operating Manual CMGZ432 FMS Force Measuring Systems AG FMS USA, Inc. FMS (UK) Aspstrasse 6 925 East Rand Road Suite 207 Highfield, Atch Lench Road 8154 Oberglatt (Switzerland) Arlington Heights, IL 60004 (USA) Church Lench Tel. 0041 44 852 80 80 Tel.

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