FS340 and FS641 High Performance Low Cost Controller for Flying Shears and Saws Precision controller for Flying Shears and Saws Easy parameter setting and immediately ready to work with minimum commissioning time High accuracy due to high feedback frequency range (300 kHz with TTL encoders and 200 kHz with HTL encoders) Extremely smooth motion by optimized S-shape profiles High dynamic response by means of short cycle time, therefore accurate cutting results also during change of line speed
Safety Instructions This manual is an essential part of the unit and contains important hints about function, correct handling and commissioning.
Table of Contents 1. 2. 3. Available Models .......................................................................................................... 4 Introduction................................................................................................................... 5 Electrical Connections ................................................................................................... 6 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7. 4. Functional description ........................................
1. Available Models The two models as shown below are available. Both models are fully similar in terms of function and performance; however there is some difference with the size, the alert outputs and the speed ratio setting. FS340: Front size 96 x 48 mm (3.780’’ x 1.890’’) Cutting length setting by keypad Analogue output 14 bits 4 power transistor outputs (alert) FS641: Front size 96 x 96 mm (3.780’’ x 3.
2. Introduction The FS340 / FS641 units are suitable for control of “Flying Shears” and “Flying Saws”, frequently used for cut-to-length applications with endless material, where the material is in continuous motion and cannot be stopped during the cutting process. The mechanical construction provides a carriage with a cutting tool, following synchronously the material while the cut is in progress, and then returning to a home position, to wait for the next cut.
+24 +5 A /A B /B - +24 +5 A /A B /B Reset, Start, Immediate Cut, Cut completed etc. RS232 Speed setpoint FS34002a_e.doc / Nov-15 Ana.out 20 mA Ana.out +/-10V GND GND Slave, B Slave, A Master, B Master, A K2 out K1 out Cont. 2 Cont.
Terminal 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Name GND +5,2V out +24V out GND Slave, /B Slave, /A Master, /B Master, /A K4 out K3 out Cont.4 Cont.3 (PROG) RxD Ana.out 20 mA Ana.out +/-10V +Vin +5,2V out +24V out GND Slave, B Slave, A Master, B Master, A K2 out K1 out Cont.2 Cont.1 Com+ (K1-K4) TxD GND GND Function Common Ground Potential (0V) Aux. output 5.2V/150 mA for encoder supply Aux.
3.1. Power Supply The FS340 synchronizer accepts both, a 17 – 40 volts DC power or a 24 volts AC power for supply via terminals 17 and 1. The current consumption depends on the level of the input voltage and some internal conditions; therefore it can vary in a range from 100 – 200 mA (auxiliary currents taken from the unit for encoder supply not included). 3.2. Auxiliary Outputs for Encoder Supply Terminals 2 and 18 provide an auxiliary output with approx. +5.2 volts DC (300 mA totally).
3.4. Control Inputs Cont.1 – Cont.4 These inputs can be configured for remote functions like Reset, Start, Cut completed, Immediate cut or display selection purpose. All control inputs require HTL level. They can be individually set to either NPN (switch to -) or PNP (switch to +) characteristics. For applications where edge-triggered action is needed, the menu allows to set the active edge (rising or falling). The Control inputs will also accept signals with Namur (2-wire) standard.
4. Functional description 4.1. Principle of operation The shear or saw blade is fixed on a carriage that can move in forward and reverse direction, under control of a +/- 10 volts speed reference signal, with a 4-quadrant DC or Servo or Vector drive. Initially, the carriage keeps waiting in its rear home position, while the controller counts the current length of the passing material by means of encoder signals from a line roll or a measuring wheel.
4.2. System Configuration As a master drive, either the motor of a feed roll or a measuring wheel equipped with an incremental encoder is used. The encoder resolutions should be at least 5 times higher than the maximum acceptable cutting error. At maximum line speed, the master encoder frequency should be at least about 1 kHz, for best resolution of the analogue output.
5. Keypad Operation An overview of all parameters and explanations can be found under section 7. The menu of the unit uses four keys, hereinafter named as follows: P PROG UP DOWN ENTER Key functions depend on the actual operating state of the unit. Essentially we have to describe three basic states: Normal operation General setup procedure Direct fast access to scaling factors 5.1. Normal Operation In this mode the unit operates to the settings defined upon setup.
Step 00 State Key action Normal operation Level: Parameter group 03 04 Level: Parameter numbers 05 06 Level: Parameter values > 2 sec. F01 Display of the Parameter group 5x F02 … F06 Select group # F06 F06.050 2x Confirmation of F06. The first parameter of this group is F06.050 Select parameter 052 09 10 F06.051… F06.052 0 8x 1 …. 8 F06.
5.4. Change of Parameter Values on the Numeric Level The numeric range of the parameters is up to 6 digits. Some of the parameters may also include a sign. For fast and easy setting or these values the menu uses an algorithm as shown subsequently.
5.5. Code Protection against Unauthorized Keypad Access Parameter group F09 allows to define an own locking code for each of the parameter menus. This permits to limit access to certain parameter groups to specific persons only. When accessing a protected parameter group, the display will first show “CODE” and wait for your entry. To continue keypad operations you must now enter the code which you have stored before, otherwise the unit will return to normal operation again.
6. Menu Structure and Description of Parameters All parameters are arranged in a reasonable order of functional groups (F01 to F09) You must only set those parameters which are really relevant for your specific application. Unused parameters can remain as they actually are. 6.1. Summary of the Menu This section shows a summary of the parameter groups, with an assignment to the functional parts of the unit.
F06 046 047 048 049 050 051 052 053 054 055 056 057 F07 058 059 060 061 062 063 F08 064 065 066 067 068 069 070 071 Command Assignment Key Up Function Key Down Function Key Enter Function Input 1 Configuration Input 1 Function Input 2 Configuration Input 2 Function Input 3 Configuration Input 3 Function Input 4 Configuration Input 4 Function Reserved Serial communication Unit Number Serial Baud Rate Serial Format Reserved Reserved Reserved Special functions Input Filter Trigger Threshold 1 Trigger Threshol
6.2. Description of the Parameters Prior to register setting you must decide which dimensions or length units (LU) you like to use for preset of the cutting length. This could be 0.1mm or 1mm or 0.001 inch or any other resolution you desire. All further settings refer to the Length Units you decided to use. E.g. when you chose to set the length with a 0.1 mm resolution, 1000 LUs will represent a length of 100.0 millimeters with all further entries. 6.2.1. Length Setting F01 F01.
F02 F02.006 Integration Time: Time constant for the phase integrator, which avoids positional errors. To be entered as number of cycles (1 cycle = 250 µsec) per increment F02.007 Correction Divider: Function to provide a digital attenuation of the phase correction signal that is produced, when the drive on mechanical grounds (dead band or backlash) cannot respond. In such a case, it is not desirable to make corrections immediately.
F02 F02.009 Synchron Time: This is an adjustable delay time between reaching the synchronous speed and switching on the “Ready to cut” output. Setting range 1-9999 milliseconds. Under regular conditions the carriage will be in the correct cutting position immediately after completion of the acceleration ramp, and the Sync Time register can be set to its minimum value of 1 ms.
F02 F02.013 F02.014 F02.015 F02.016 F02.017 Max. Master Frequency: Sets the expected maximum input frequency on the Master encoder input, i. e. the line encoder frequency at maximum line speed. You should add a 10% reserve to the real maximum frequency. The unit will not process frequencies higher than this setting. Cut Window: Sets a tolerance window scaled in length units around the cutting position where the carriage must be before the “Ready to cut” signal is switched on.
F02.018 F02.019 F02.020 F02.021 Jog Ramp: Ramp time in seconds for Jog operations with respect to speed changes between standstill and maximum speed (setpoint 10 V) Min. Position, Max. Position: Programmable software limit switches scaled in length units for the extreme forward and rear carriage position. The settings refer to the “Zero” Position, which is set by the “Set Zero Position” input. In general (but this is not a “must”), the Zero position is also used as the “Home” Position.
The following drawings explain the function of the software limit switches, based on the following settings (example): “Min.Position” = -20 LU, “Max.Position” = +2500 LU, “Alarm Position” = 2000 LU: Carriage travel range Carriage disabled in backward direction No function -20 Min Pos. -20 Min Pos. F02.023 0 Zero Pos. +2000 Alarm Pos. Carriage travel range Unit trips to Error state, when Min. Pos. is touched F02 F02.022 Carriage disabled in forward direction 0 Zero Pos. +2500 Max Pos.
6.2.3. Definitions for the Master Encoder F03 F03.026 Encoder properties 0= Differential Impulses A, /A, B, /B (2 x 90°) incl. inv. 1= Single-ended Impulses A, B (2 x 90°) without inv. F03.027 Edge counting 0= Simple edge evaluation (x1) 1= Double edge evaluation (x2) 2= Full quadrature edge evaluation (x4) F03.028 Counting direction 0= Up when A leads B 1= Down when A leads B F03.029 Speed Display Factor Multiplication factor to calculate the speed display value from the master frequency (see chapter 7.
6.2.4. Definitions for the Slave Encoder F04 F04.032 Encoder properties 0= Impulses A, /A, B, /B (2 x 90°) incl. inv. 1= Impulses A, B (2 x 90°) without inv. F04.033 Edge counting 0= Simple (x1) 1= Double (x2) 2= Full quadrature (x4) F04.034 Counting direction 0= Up when A leads B 1= Down when A leads B F04.035 n.a. n.a. = not applicable Range 0…3 Default 1 0…2 0 0…1 0 6.2.5. Analogue output definitions F05 F05.
6.2.6. Key command assignments F06 F06.046 Function assignment to key „UP“ 0= No function 1= Reset 2= Start 3= Immediate Cut 4= n.a. 5= n.a. 6= Set Zero position 7= Store to EEPROM 8= Scroll Display 9= n.a. 10= Jog forward 11= Jog backward 12= Clear Batch Counter 13= n.a. 14= Read front thumbwheels (model FS 641 only) 15= Clear Error 16= n.a. F06.047 Function assignment to key „DOWN“ See key „UP“ F06.048 Function assignment to key „ENTER“ See key „UP“ n.a. = not applicable FS34002a_e.
6.2.7. Characteristics and functions of the Control Inputs F06 F06.049 Switching characteristics of input „Cont.1“ 0= NPN (switch to -), function active LOW 1= NPN (switch to -), function active HIGH 2= NPN (switch to -), rising edge 3= NPN (switch to -), falling edge 4= PNP (switch to +), function active LOW 5= PNP (switch to +), function active HIGH 6= PNP (switch to +), rising edge 7= PNP (switch to +), falling edge F06.050 Function assignment to input „Cont.
Unconnected NPN inputs are always HIGH (internal pull-up resistor) Unconnected PNP inputs are always LOW (internal pull-down resistor) 6.2.8. Serial communication parameters F07 F07.058 Serial device address (unit number) F07.059 Serial baud rate 0= 9600 Baud 1= 4800 Baud 2= 2400 Baud 3= 1200 Baud 4= 600 Baud 5= 19200 Baud 6= 38400 Baud F07.
6.2.9. Special functions F08 F08.064 F08.065 F08.066 F08.067 Range 0…3 30 … 250 30 … 250 0…4 Default 0 166 166 0 Range Default Digital input filter: must be set to “0”. Trigger threshold for encoder1 inputs *) Trigger threshold for encoder2 inputs *) Brightness of the 7-segment LED display 0= 100% of maximum brightness 1= 80% of maximum brightness 2= 60% of maximum brightness 3= 40% of maximum brightness 4= 20% of maximum brightness F08.068 Frequency Control: must be set to “0” 0…1 0 F08.
7. Description of Commands and Outputs 7.1. Commands No. Command 1 Reset 2 Start 3 Immediate Cut 4 Cut completed 5 6 n.a. Set Zero Position FS34002a_e.doc / Nov-15 Description Sets the internal differential counter and the analogue correction signal to zero. Both drives run solely in analogue synchronization (open loop) whilst activated Start of the automatic cutting procedure. The unit cuts automatically to preset cutting length.
No. Command 7 Description Store to Stores actual operational settings to the EEPROM, so EEPROM they remain available also after power down. 8 Scroll Display Selects the source of the digital display. See chapter 7.3 Display for details. 9 Parameter Disables the keypad for any parameter access. Only Disable commands assigned to the keypads will be accessible 10 Jog Forward Moves the carriage in one or the other direction (Jog speed register settable).
7.2. Outputs No. K1 Output Error: This output goes high when an error is detected during operation (see section 7.4 “Error Messages”). K2 Alert: This output is set when during forward motion the carriage reaches the “Alarm Position”. It can be used to limit the traveling range of the carriage into forward direction during production. If, e.g.
7.3. Display of Actual Values During normal operation it is possible to display an actual value. Two LEDs at the front panel indicate the actual value displayed. You can scroll the actual value on the display by Scroll Display command, which can be assigned either to a key or to an input. Parameter F08.071 “Default Display” selects the actual value to be displayed after power up of the unit. Nr.
7.4. Error Messages Upon detection of an error, the carriage remains in a closed-loop standstill at home position after termination of the current cut. Output “Error” switches to high and the unit displays a flashing error message “Error…” indicating the error number. To clear an error state either set “Clear Error” command or cycle the power supply of the unit. Please note that the unit will immediately return to the error state if the cause for the error has not been eliminated. Error No.
8. Steps for Commissioning For easy and uncomplicated commissioning of the FS340 / 641 controllers you need a PC with the actual operator software OS3.x. You can download this software and full instructions, free of charge, from our homepage www.motrona.com. Connect your PC to the synchronizer as shown in section 3.6 and start the OS3.x software.
After entry of all parameters click to “Transmit All” followed by “Store EEPROM” to store all parameters to the FS340 or FS641 controller. At this time, both drives (line and carriage) must be adjusted to proper and stable operation over the full speed range. Carriage drive settings must provide a maximum of dynamics and response (set ramps to zero, switch off any integral or differential component of the internal speed control loop, i.e.
8.2. Set Directions of Rotation The direction of rotation must be defined for both, master and slave encoder. Make sure the Reset is switched on when you do this (the softkey must show “Reset is ON”) Move the Master encoder into forward direction (manually or by means of a remote speed signal to the Master drive). Observe the “Counter Master” value shown in the monitor window on the right. It must count up to positive values.
8.4. Setting of the Proportional Gain The register “Gain Correction” determines how strong the controller responds to position and speed errors of the drive. In principle, this setting therefore should be as high as possible. However, depending on dynamics and inertia of the whole system, too high gain values will produce stability problems. Please try to increase the setting of Correction Gain from 0.500 to 1.000, 1500, 2.000, 2.500, 3.000 etc.
If during forward acceleration the position error takes high positive values and the bar graph moves to the extreme right position, this indicates that the carriage drive cannot follow the acceleration ramp and you should decrease the “Acceleration 1” setting. The same is valid for “Acceleration 2”, when during reverse acceleration you observe high negative errors and the bar graph moves to the extreme left.
9. Appendix for model FS 641 9.1. Relay Outputs While model FS340 provides high-speed transistor outputs only, model FS641 provides four additional relay outputs, operating in parallel to the high-speed transistor outputs K1 – K4. All electrical connections of FS 641 are fully similar to FS 340, except that with FS 641 models the back plane is equipped with an additional terminal strip X3 providing the relay connector: 1 2 3 4 5 6 7 8 9 10 11 12 REL.4 C = NO = NC = REL.3 REL.
10. Specifications and Dimensions AC power supply DC power supply Aux. encoder supply outputs: : : Inputs : Counting frequency (per encoder) : Switching outputs (all models) : Relay outputs (models FS641 only) : Serial link Analogue outputs : : Ambient temperature : Housing Display Protection class (front side only) : : : Protection class rear side Screw terminals : : Conformity and standards: (a) (b) 24 V~ +/-10%, 15 VA 24V- (17 – 40V), approx.
Dimensions of model FS340: 110,0 (4.331’’) 91,0 (3.583) 48,0 (1.890) 10,0 (.394) 44,0 (1.732) 8,0 (.315) 96,0 (3.780’’) 9,0 (.345) 129,0 (5.079) 140,5 (5.531) Panel cut out: 91 x 44 mm (3.583 x 1.732’’) FS34002a_e.
Dimensions of model FS641: 110,0 (4.331’’) 88,5 (3.484) 8,0 (.315) 10,0 (.394) 90,5 (3.563) 96,0 (3.780’’) 12,0 (.472) 111,5 (4.39) 96,0 ( 3.78 ) With optional plexi glass cover for protection class IP65 (motrona part # 64026) 9,0 (.345) 129,0 (5.079) 140,5 (5.531) 18,5 (.728) Panel cut out (b x h): 89 x 91 mm (3.504’’ wide x 3.583’’ high) FS34002a_e.
