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Motrona FS150 Operating Instructions Manual

High performance flying shear control
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FS150
High Performance Flying Shear Control
 Stand alone controller for "Cut on the fly" applications
 Can operate with Servo- or DC- or AC- inverter drives
 High accuracy, 300 kHz input frequency
 Highly dynamic, 150 sec response time
 Easy remote length preset by thumbwheel switches or PLC or host computer
 Easy LCD display setting or PC setting via serial link
 RS232/RS485 and CANopen interface
 Speed transitions by sin² profile. Speed variable anticipation for carriage start.
 Print mark registration and batch counters included.
Operating Instructions
FS15016C_e.doc / Nov-15
Page 1 / 59

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Summary of Contents for Motrona FS150

  • Page 1 FS150 High Performance Flying Shear Control  Stand alone controller for “Cut on the fly“ applications  Can operate with Servo- or DC- or AC- inverter drives  High accuracy, 300 kHz input frequency  Highly dynamic, 150 sec response time ...
  • Page 2  - Errors and omissions excepted – Version: Description: FS15016N/ TJ/ Oct. 03/ Max. 8 print marks between sensor and home position Page/21/26/42 Control word and status word Encoder inputs levels and max. frequency FS15016C_d/Bo/Jul-08 Modification to motrona format FS15016C_e.doc / Nov-15 Page 2 / 59...

  • Page 3: Table Of Contents

    Table of Contents 1. Introduction ........................5 2. Principle of Operation ....................6 3. Hardware Configuration ....................7 4. Wiring and Screening ....................9 4.1. Encoders ......................11 4.2. Analogue Output ....................13 4.3. Power Supply ....................... 14 4.4. Parallel Interface (PI) ................... 14 5.
  • Page 4 Compatibility Hint Versions FS15014A and higher use some different control inputs and control outputs and therefore are not fully hardware compatible to former versions! You must modify a few connections at the PI/PO connector when replacing older version against FS15014A or a higher version! See section 5. The software has been upgraded and now includes ...

  • Page 5: Introduction

    1. Introduction Flying shears are used for cutting applications, where endless material to be cut to length cannot be stopped during the cutting process and the cut must be effected “on the fly“. The mechanical construction provides a saw or shear system mounted on a carriage, that follows the material with synchronous speed while cutting is in progress, and then returns to a home position to wait for the next cut.

  • Page 6: Principle Of Operation

    When the cut is completed, the FS150 must receive a "cut complete" signal. This will cause a deceleration and a reversal of the carriage until it has reached its home position again. All speed transitions occur with a smooth sin²...

  • Page 7: Hardware Configuration

    A signal must be available to indicate completion of a cut to the FS150 controller. All control signals must be PNP (switching to positive) with a level of 18..30 volts DC. Fig. 2 shows the block diagram of the unit.
  • Page 8 +/-10V (or +10V) Master Slave Analogue- Input Input output A, /A, B, /B A, /A, B, /B Power 24VDC Ready RS232 FS150 Reverse Forward Communi- Length RS485 Carriage Alarm cation Outputs Ports Home position Gap coml. Ready to cut Control...

  • Page 9: Wiring And Screening

    On site of the power supply, the minus output must be earthed. Where the wires between power unit and FS150 controllers are longer than e.g. 1 meter, it is advisable to ground the front plate of the controller again by a separate wire, on the shortest way possible.
  • Page 10 Minus wire of the encoder supply there, but never to earth potential again! Encoder cable to encoder to FS150 Minus of encoder supply Screen Tie Minus of encoder supply and screen together whereever you interrupt the encoder cable by terminal or connectors.

  • Page 11: Encoders

    With all other cables like analogue output, control or parallel output, put the screen to the metal connector housing on the FS150 side and leave it unconnected on its peripheral side. Again avoid double earthing. The only place where the screen is earthed must be the front...
  • Page 12 FS150 at the same time, there may come up interference problems. You can use a GV150 impulse splitter to eliminate any kind of problems. In most applications, the common encoder would also work fine when it is supplied by the drive and the FS150 operates in fully differential mode like shown.

  • Page 13: Analogue Output

    The FS150 provides a 5.2 V encoder supply and at the other end the encoder must at least receive its minimum supply voltage! (See encoder specifications).

  • Page 14: Power Supply

    Store the data to the EEprom by a Store pulse, when you like the unit to use same data again after power down. It is easy to see how 8 external registers may be loaded into the FS150. For operation of Read and Store inputs see section 4.5.
  • Page 15 Important Advice Upon power up, the unit loads the full register set stored in its EEProm. Data transmitted from the parallel and/or serial interface will overwrite the operational RAM data, but not the corresponding EEProm registers. As a result, when powering up, any parallel or serial data will be replaced by EEProm data, until it is overwritten again.
  • Page 16 +24V S4 S3 S2 S1 Select Length 1 (C 02) Lines Length 2 (C 03) Virtual Line on +/- Sync (C 06) BCD1 BCD2 Low order Accel 1 (C 04) BCD4 digit Accel 2 (C 05) BCD8 (LSD) Sync Time (C 07) BCD1 BCD2...

  • Page 17: Control In / Out Port (Pi/Po)

    5. Control IN / OUT Port (PI/PO) There are 12 input lines and 8 output lines for remote control purpose. Reset Jog. forward Jog reverse Read and activate PI data Start gap Cut completed Inputs Store data to EEProm Start/Stop Immediate cut Length select / print mark Set zero position...
  • Page 18 Inputs Description Cut completed This input must receive a signal when a cut has been completed. The (23): direction of the signal (High/Low) is register selectable. With the selected edge the FS 150 will start deceleration and reversal in order to put the carriage back to its rear home position.
  • Page 19 Outputs Description Ready (5): A high signal indicates the unit is ready to operate and a low signal indicates the unit is out of order or an error has been detected and the unit has switched off the control loop (see “Errors“). When high, the unit could not detect a fault by itself, but this is not a guarantee that the whole system is ready to work.

  • Page 20: The Serial Port

    When using the RS485 interface, you can serve up to 32 different bus participants in either 2-wire or 4-wire transmissions mode. The subsequent figures show, as an example, how to run a TX720 operator terminal with a FS150 unit and other controllers. FS15016C_e.doc / Nov-15...
  • Page 21 Other devise Fig 21 Fig 22 A detailed description of the serial protocol is available upon request or can be downloaded from the Download site of the motrona homepage www.motrona.com document name: „Serpro“ FS15016C_e.doc / Nov-15 Page 21 / 59...

  • Page 22: Register Settings

    7. Register settings Registers can be set by keypad under LCD control or by PC, using the OS3.2 operator software. This section describes the registers and their meanings and the next section shows how to program the registers. The unit provides 4 Sub-Menus. Data In Contains operational registers.

  • Page 23: How To Operate The Keypad

    8. How to operate the Keypad LCD-Display Processor 123456 78 Fig 23 To access the operator PCB, remove right hand side plate. The on board setting controls comprise an LCD display, 4 small buttons and a sliding switch. When the switch is selected to "Run", the LCD permanently displays the software version of the program and the buttons A, B, C and P have no function.
  • Page 24 Action  Slide the switch to “PRG  Select the Data IN Menu by pressing “P“  Press “A“ several times until the LCD shows “Accel 1“  Select the Accel 1 register by P and read the actual setting (i.e.1000) Change setting to i.e.
  • Page 25 Data IN Set - up Adjust Testprog Pulse Line/1000 Mode Gain - Cor Mast - Dir Pulse Cut/1000 1Q/4Q Gain - Tot Slav - Dir Length 1 PI-Format Offs - Cor Length 2 Add-Correction Gain - Cor Acceleration 1 Unit-Number Offs - Tot Acceleration 2 Baud- Rate...

  • Page 26: The Data In - Menu

    9. The Data IN – Menu Register Description Pulses Line: This register calibrates the encoder ppr of the line encoder. You must find out how many impulses we receive when the line moves 1000 length units forward. Set the number of impulses to this register. Range 0-999 999 Pulses Cut: This register calibrates the encoder ppr of the carriage encoder.
  • Page 27 Register Description Speed ACC 1 ACC 1 Sync speed Time Fig.25 ACC 2 ACC 2 +/- Synchron This register allows to slightly vary the synchronous speed in a range of Rate: +/-9.99%. In general, this register will be set to 0.00 and the carriage will synchronize with the line exactly according to the encoder information.
  • Page 28 Register Description Integration Sets the integration in order to avoid cutting errors caused by non-linearity of Time: the carriage drive. 00 = Integrator off 01 = Fast integration 99 = Slow integration For setting see section “Steps for commissioning“. Cut Window: Sets a tolerance window around the cutting position where the carriage must be before the “Ready to cut“...
  • Page 29 Register Description Edge sense: Sets the active edge for the external “Cut completed“ signal Rising edg e at input “C ut completed” H IGH terminates the syn chronous phase and st arts the return cycle Falling edg e at inp ut “Cut completed” HIGH terminates the syn chronous phase Fig.28...
  • Page 30 8 print marks appear between the sensor and the carriage home position. The FS150 controller can store up to 8 print mark positions in a FIFO shift register and cut accordingly.
  • Page 31 Register Description Fig. 32 Dead Band: For use with 1-quadrant inverter drives only: Provides a delay bet-ween the forward output signal and the reverse output signal to avoid overlapping of the for/rev select. Adjustable in milliseconds. Range 0 - 9999msec. Dead Band Forward output...
  • Page 32 “ready to cut”-signal is switched on. This function should only be used for systems with poor dynamic performance. Please note that too high settings of this parameter will probably cause the FS150 controller to give no “ready to cut”-signal at all! Setting range: 1 – 9999 FS15016C_e.doc / Nov-15...

  • Page 33: Setup Menu

    Unit NR: Attaches a device number to the FS150 controller for serial communication. Setting from 11 to 99. It is not allowed to use device numbers containing a “0“ (i.e. 09 or 20) since those are reserved for collective addressing of several units.
  • Page 34 Range 0 - 999 999. For setting see “Steps for Commissioning“. Remark for offset settings: FS150 uses precision operational amplifiers with a zero offset error of less than 1mV and the offset register can be set to zero normally. With extended installations however, an offset voltage can build up in the cables, caused by small balance currents between the different devices.

  • Page 35: Adjust Menu

    11. Adjust Menu There are only the parameters Gain-Cor and Gain-Tot accessible (the same as described above), but in this menu they can be changed continuously with the motors running. This allows easy adjustment of the analogue synchronization and the intensity of correction while observing the LED bar graph and the drives.

  • Page 36: The Led Display

    13. The LED Display The 8 Led’s mounted on front of the module indicate the instantaneous positional error between the real carriage position and the position where it should be in respect to the line. The display provides information for commissioning and fault monitoring, in a very simple form. Fig.

  • Page 37: Remarks About Drives, Encoders, Cables, Installation

    The cross section of encoder cables must be chosen with consideration of voltage drop on the line. The FS150 provides a 5.2 V encoder supply and at the other end the encoder must at least receive it‘s minimum supply voltage! (See encoder specifications).
  • Page 38 (i.e. RC filters in parallel to coils of AC contactors, diodes in parallel to electromagnetic DC values etc.) Make sure your cabinet and your machine have a solid earthing/grounding system. FS150 possesses excellent features with EMC immunity, but it can fail under poor electrical environment conditions.

  • Page 39: Steps For Commissioning

    Make sure the drive can run the maximum speed with a speed reference of 9 Volts already (We must leave 1 Volt of output swing for the FS150 to make corrections). For the setup procedure it is best to mechanically disconnect the motor shaft from the carriage, so we can run the motor continuously and need not to observe the mechanical limitations of the carriage.
  • Page 40 15.3. Power the unit up, connect the serial cable to the PC and start the OS3.2 software. Fig 38 15.4. Set all registers according to need. For Virtual line speed select a small value (e.g. 10m/min) for the first steps. Also it is better to start with lower acceleration values and to optimize them later.
  • Page 41 Setting of registers “Mast-Dir“ and “Slave-Dir“ is not important at this time. Click “Transmit All“ and then to “Store EEprom“ to store your settings to the FS150 controller. 15.5. We must first set the counting direction of the encoders. Select the “Test“ function in the “Tools“...
  • Page 42 Click to the “Master Direction“ field. Rotate the Master encoder in forward direction, e.g. the direction it will rotate later with the material. The counter in the Master Direction field must count up. Where you find we count down, click “Change direction“. When we count up, click to the “Direction Slave“...
  • Page 43 We must observe the color bar graph and the differential counter now while we adjust the “Gain Total“. Gain Correction should always be set to 200 during this procedure. When we click the Reset to “ON“, our differential counter will show zero and the bar graph will be in its green center position.
  • Page 44  Put the carriage to the desired Home position by using the Jog function. Where your software limit switches would not allow you to reach the desired position, keep the “Set zero position“ input High while you jog.  Make sure your software limit switches (Min-Position, Max-Position, Alarm Preset) are correctly set so the carriage can move over the desired range.
  • Page 45  Keep the cutting time of the saw blade or shear as short as possible to reduce cycle time. This concludes the setup procedure of the FS150 Flying Shear Control. We recommend you to store your settings on a disc or the hard disc of your PC. In case of exchange of the unit you just need to load down the parameter file to the controller to be ready for production again.

  • Page 46: Alarm States And Conditions

    There is one alarm situation that needs to be controlled by remote customer circuit individually according to demand: In automatic operation, the FS150 provides a High signal at the carriage alarm output when, during forward motion, the carriage position exceeds the preset level. The unit however will not stop the drive nor trip, but just signal that the preset position has been exceeded.

  • Page 47: Accuracy Considerations

    17. Accuracy considerations It is easy to understand that the FS150 controller functions are based on correct information from the encoders. When you observe the LED at the moment when a cut takes place, you can easily see what the theoretical cutting error can be. In practical applications, with the drive and the unit properly adjusted, the cutting error should be limited to 4-7 encoder increments and the resolution of the encoders will give the real error expressed in length units.
  • Page 48 Measure the first piece of material that has been cut after the line has been started and compare its length with the length preset of the FS150 controller. If the measured length is shorter than the length preset the value of parameter “Pulses Line/1000” is too low and must be increased.

  • Page 49: Which Shortest Length Can We Cut At A Certain Line Speed

    18. Which shortest length can we cut at a certain line speed? Flying shears have physical limitations in respect to short cutting length at high line speeds and not every length can be cut at any line speed. This should be shown by the following example: When we would need to cut pieces of 1 meter length at a line speed of 60 meters/minute, this means we must execute one cut every second.

  • Page 50: Which Maximum Line Speed Can We Use With A Certain Cutting Length

    19. Which maximum line speed can we use with a certain cutting length We need to separate two length ranges to calculate the maximum line speed. a. When our maximum line speed must not exceed b. When our maximum line speed can be 20.

  • Page 51: Auxiliary Register And Command Codes

    21. Auxiliary Register and Command Codes The following auxiliary registers are accessible by serial link, with the access codes shown (R = Read only, R/W = Read/write) Code Name Function Error Count Shows the differential number of encoder increments between the scheduled carriage position and the real carriage position at any time LV value Represents the actual feed forward signal (speed profile)
  • Page 52 Beside the serial access codes shown in this manual, the subsequent codes are available to execute the same commands that can be activated by the hardware inputs also: Code Bit of control word (86) Function Type Length select Read PI data Cut completed Start/Stop Immediate cut...

  • Page 53: General Master Reset And Erase Of Eeprom

    22. General Master Reset and Erase of EEProm The unit carefully checks all entry data for validity and correctness within their permitted numeric range. If, as an extreme exception, invalid data should intrude into the register range, bad function or even a full hang-up could be the result. If this should ever happen ...

  • Page 54: The By 106-X Remote Thumbwheel Switch

    23. The BY 106-X Remote Thumbwheel Switch BY106 72,5mm max. 1,5 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 2 Screwt erminals, D EC.1 D EC.2 DEC.3 D EC.4 DEC.5 12 positions ea ch...

  • Page 55: Dimensions And Specifications

    24. Dimensions and Specifications RS232 PI/PO MASTER SLAVE ANALOG 55,5 70,5 Front view Side view Top view Rear view Fig 50 FS15016C_e.doc / Nov-15 Page 55 / 59...
  • Page 56 Power supply 18...30 V unstabilized Consumption approx. 300 mA (plus 25% of the encoder supply currents, if internal encoder supply used) Encoder Supply Aux. voltage 5.2 V, max. 400 mA installed Processor H8/532 with 20 MHz clock frequency PCB and Technology SMD, Multiplayer PCB`s, High speed logic 74 HCT Encoder Inputs Two A, /A, B, /B, Z, /Z (5 V TTL opto-isolated)

  • Page 57: Serial Code List

    25. Serial Code List 25.1. Parameter # Menu Name Code Default DATA-IN Pulses Line/1000 999999 10000 DATA-IN Pulses Cut/1000 999999 10000 DATA-IN Length 1 999999 1000 DATA-IN Length 2 999999 1000 DATA-IN Acceleration 1 999999 5000 DATA-IN Acceleration 2 999999 5000 DATA-IN +/- Synchron Rate...

  • Page 58: Inputs

    Menu Name Code Default SET-UP Mode SET-UP 1Q/4Q SET-UP PI-Format SET-UP Add-Correction SET-UP Ser. Unit Number SET-UP Ser. Baud Rate SET-UP Ser. Data Format SET-UP Bus Address SET-UP Bus Baud Rate SET-UP Bus Config. SET-UP Bus Tx Parameter SET-UP Bus Rx Parameter SET-UP Master Direction SET-UP...

  • Page 59: Variables

    25.3. Variables Name Code Notes tstcou ":0" Internal Using diff1 ":1" lvwert ":2" lengcoh ":3" Internal Using cutcouh ":4" integ ":5" len_p1h ":6" prdcouh ":7" (**) wstcouh ":8" v_leit ":9" 10 errsta ";0" Internal Using 11 cystah ";1" 12 poscouh ";2"...

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