AccuWeb MICRO 4000 NET User manual

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P.O. Box 7816
Madison, Wisconsin 53707-7816
Instruction Manual
MICRO 4000®NET Web Guide Control System
Software Versions:
M4K 23.xx
DLG 21.xx
RMT03 GP21.xx
RMT03 AR21.xx
Document P/N 990040-230 (Rev. 1)
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Table of Contents
NET Web Guide Control System .............................................................................3MICRO 4000®
Introduction................................................................................................................................4
Installation..................................................................................................................................7
Operation.................................................................................................................................10
Troubleshooting.......................................................................................................................11
Appendix 1 / Motor Drive Calibration.......................................................................................15
NET Controller........................................................................................................16MICRO 4000®
Introduction..............................................................................................................................17
Parameters..............................................................................................................................17
Appendix 1 / Parameter Summary ..........................................................................................39
Appendix 2 / Error Codes........................................................................................................42
Appendix 3 / Oscillation Function (Optional)...........................................................................43
Appendix 4 / Inhibit Input.........................................................................................................45
Appendix 5 / Discrete Isolated Inputs......................................................................................46
Appendix 6 / Discrete Isolated Outputs...................................................................................48
Appendix 7 / Analog Inputs and Outputs.................................................................................50
PointSource™, WideArray™, and Hi-Temp Edge Detectors.........................................................55
Introduction..............................................................................................................................56
Setup .......................................................................................................................................57
Calibration................................................................................................................................58
Maintenance............................................................................................................................59
3 Digital Line Guide Sensor......................................................................................60AccuBeam®
Introduction..............................................................................................................................61
Installation................................................................................................................................62
Operation.................................................................................................................................63
Calibration................................................................................................................................65
Parameters..............................................................................................................................71
Keypad Lock............................................................................................................................78
Troubleshooting.......................................................................................................................79
Maintenance............................................................................................................................80
Appendix 1 / Parameter Summary ..........................................................................................81
Appendix 2 / Line Guide Test Pattern .....................................................................................82
Linear Actuators...........................................................................................................83AccuWeb®
Introduction..............................................................................................................................84
Setup .......................................................................................................................................84
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Maintenance............................................................................................................................85
Remote Station - Guide Point Adjust.............................................................................................88
Introduction..............................................................................................................................89
Installation................................................................................................................................89
Operation.................................................................................................................................90
Parameters..............................................................................................................................91
Keypad Lock............................................................................................................................95
Troubleshooting.......................................................................................................................96
Remote Station - Auxiliary..............................................................................................................97
Introduction..............................................................................................................................98
Installation................................................................................................................................98
Operation.................................................................................................................................99
Keypad Lock..........................................................................................................................100
Troubleshooting.....................................................................................................................101
Fieldbus Interface.........................................................................................................................102
Introduction............................................................................................................................103
Installation..............................................................................................................................103
Programming Information......................................................................................................104
Troubleshooting.....................................................................................................................116
Appendix 1 / DeviceNet Interface..........................................................................................117
Appendix 2 / Profibus Interface .............................................................................................120
Appendix 3 / ControlNet Interface .........................................................................................123
Appendix 4 / Modbus Plus Interface......................................................................................126
Appendix 5 / Ethernet TCP/IP and Modbus/TCP Interface...................................................130
Service / Return Authorization .....................................................................................................134
Restocking Policy.........................................................................................................................135
Warranty Policy............................................................................................................................136
Installation Drawings....................................................................................................................137
Important! Make sure the first two digits of the software version numbers shown on the cover of
this manual match the first two digits of the version numbers displayed by your controller, digital
line guide or remote station. If they do not match contact AccuWeb to obtain the correct manual.
AccuBeam®, AccuWeb®, MICRO 1000®, and MICRO 4000®are registered trademarks of
AccuWeb, Inc.
PointSource™ and WideArray™ are trademarks of AccuWeb, Inc.
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MICRO 4000®NET Web Guide Control System
MICRO 4000NET Web Guide Control System 3
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Introduction
The MICRO 4000 NET Web Guide Control System is a microprocessor-based control system for
medium to large-sized web guides. It is compatible with AccuWeb’s dynamically compensated
ultrasonic and infrared edge detectors, digital line guide, remote stations, and all linear actuators.
A MICRO 4000 NET system can include up to seven main components:
1. Edge Detector or Line Guide Sensor
PointSource and WideArray Compensated Edge Detectors
Ultra-compact housing
Available with sensing areas ranging from 0.2” to 18.6” wide [5mm to 472mm]
Available with gap widths ranging from 1.5” to 4” [38mm to 102mm]
Fully compensated for temperature, humidity, dust, and most other process contaminants
Immune to passline variation and web flutter
Suitable for long cable length applications
Intrinsically-safe models available for hazardous environments
Ultrasonic models are ideal for transparent or opaque film, paper, and foil web materials
Infrared (IR) models are ideal for non-wovens and other porous web materials
Hi-Temp Compensated Ultrasonic Edge Detector
Withstands oven temperatures up to 500 deg F [260 deg C]
Available with waveguide tube lengths up to 84” [213cm]
Fully compensated for temperature, humidity, dust, and most other process contaminants
Immune to passline variation and web flutter
Suitable for long cable length applications
Intrinsically-safe models available for hazardous environments
Ideal for transparent or opaque film, paper, and foil web materials
AccuBeam 3 Digital Line Guide Sensor
Ultra-compact housing
Three light source colors and three illumination angles provide optimal lighting
Line and edge guiding modes
Pattern matching algorithm locks onto hard-to-see lines
Auto-calibration automatically selects optimum settings
Environmentally-sealed function switches and display
Suitable for long cable length applications
MICRO 4000NET Web Guide Control System
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2. MICRO 4000 NET Controller Board
Single-board design
Auto-recovery after power interruption
Non-volatile memory for user-settable parameters and operating modes
On-board parameter entry keypad and display
Two edge detector inputs for centerline guiding
Serial I/O port for remote station and digital line guide
Analog ±10 VDC output for controlling motor drive
Actuator end-of-travel inputs:
Potentiometer input for electronically-adjustable limits
Limit switch inputs for fixed limits
Opto-isolated inhibit input
Opto-isolated fault indicator output
Auxiliary analog and digital I/O
Input voltage: 90-132 VAC or 180-264 VAC, 50/60 Hz, single-phase
3. MICRO 4000 NET PWM Motor Drive
Fast, accurate response to web movement
Drives brush or brushless DC motors up to 746 watts (1.0 HP)
4. MICRO 4000 NET Enclosure
Low
profile
Environmentally-sealed function switches
Cam-locked door with double-bit insert key
External mounting feet
5. AccuWeb Linear Actuator
Available with brush or brushless DC motors up to 746 watts (1.0 HP).
Available with standard stroke lengths up to 6” [152mm] (other lengths available upon
request)
Available with limit switches or potentiometer for sensing end-of-travel limits and servo-
center position
MICRO 4000NET Web Guide Control System 5
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6. Fieldbus Interface (optional)
Links the MICRO 4000 NET system with a remote PLC or computer through a fieldbus
network
Compatible with most fieldbus protocols, including DeviceNet, Profibus, ControlNet,
Modbus Plus, Modbus/TCP, and Ethernet TCP/IP
Provides control of operating mode, guide point position, and other functions
Permits monitoring of actuator position, web position, and other status indicators
7. Remote Station (optional)
Rugged, ultra-compact housing
Remote guide point adjustment or remote access to digital line guide’s front panel
Environmentally-sealed function switches and display
Product Specifications:
Enclosure size (H x W x D): 9.84” [250mm] x 11.81” [300mm] x 5.91” [150mm]
Power requirements: 90-132 VAC or 180-264 VAC, 50/60 Hz, single-phase
Operating
environment:
Maximum ambient temperature 120 deg F [48.9 deg C]
Humidity 0-90% non-condensing
MICRO 4000NET Web Guide Control System
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Installation
The MICRO 4000 NET system has been tested, calibrated, and run at the factory in a
closed-loop configuration. After installation, most systems may be started up and operated
without further adjustment. Refer to the connection and wiring diagrams on page 137 for cable
installation information.
OEMs: If shipping clamps and spreaders are removed, make sure that they are re-installed
prior to forwarding to the final destination. Verify that all mechanical and electronic
components are secured for shipment.
1. Linear Actuator and Guide
Install the web guide and linear actuator into the machine. Refer to the guide and actuator
application drawings on page 137 for installation information. Once the web guide is installed,
it must be trammed to the rest of the machine.
Note: Make sure the actuator is in the servo-center position before tramming the web guide.
This may not be possible until after step 5, below.
Important: Special attention must be given to the actuator mounting. Any mechanical
compliance or backlash in the actuator mounting will seriously affect guiding accuracy.
Deflections of a few thousandths of an inch will reduce the performance of the system. Also,
an anti-rotation bracket is required for most applications. The actuator must be allowed to
gimbal slightly on the ball rod ends to accommodate minor actuator mounting misalignment.
2. Sensor (Edge Detector or Digital Line Guide)
Install the sensor (edge detector or digital line guide). Refer to the guide and sensor
application drawings on page 137 for installation information. Use of the AccuWeb edge
detector mounting bracket simplifies installation and adjustment.
The sensor cable should be long enough so that the sensor may be repositioned if the web
width or web path changes. The standard cable length is 12 feet. Longer cables are available
upon request.
Note: The cables supplied with the system have been chosen for specific shielding and
capacitance properties. DO NOT splice or replace these cables with any other style or
configuration of cable. This can cause serious degradation or complete loss of system
performance. DO NOT SPLICE CABLES. Longer cables are available upon request.
3. Control Enclosure
Install the control enclosure on a rigid mount such as a wall or secure framework. Do not
install the control enclosure on the side of a dryer or in other high temperature areas. Also, do
not install the control enclosure on a moving winder structure.
4. Electrical Power
Note: Electrical power must be provided from a customer-supplied disconnect. Connections
must comply with NEC 590 and other local codes.
a) Verify that the power source is off and locked out.
b) Install the electrical power cord through the right-most cord grip.
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c) Connect the cable to the terminal block located inside the enclosure.
d) Make sure the circuit board is free of metallic debris such as screws, lockwashers, and
wire strands.
e) If any of the cables have been removed, shortened, or modified in any way, make sure
the connections agree with the appropriate connection and wiring diagrams located on
page 137.
5. Static Test
a) Apply power to the system.
b) Press the MANUAL button.
c) Press the IN and OUT buttons several times. The actuator and web guide mechanism
should move freely and without hesitation.
d) Press and hold the IN button. When the guide mechanism gets near the In limit, release
the button.
e) Jog the IN button repeatedly until the actuator automatically stops at its end-of-travel
limit.
Caution: If the actuator or web guide mechanism hits a mechanical obstruction before
the actuator stops automatically at its end-of-travel limit, release the button immediately.
Continued activation will cause serious damage to the actuator motor and/or guide
mechanism.
f) Repeat the previous two steps using the OUT button in order to check the Out limit.
g) Press the SERVO-CENTER button and verify that the actuator drives to the center of its
stroke.
6. Dynamic Test
a) Press the SERVO-CENTER button and verify that the actuator drives to the center of its
stroke. This also places the web guide in its center (or tram) position.
b) Thread the web through the machine and put a slight tension on it so that the web is in its
normal operating position.
Repeat steps c) through h) for each sensor:
c) Press the SERVO-CENTER button.
d) Position the sensor.
Edge detector: Place at the edge of the web. The edge detector’s null indicator LED will
turn off when the edge detector is positioned correctly. The scribed lines on the edge
detector indicate the approximate location of the detector’s guide point.
Note: The default calibration supplied with the system should work for most materials.
However, if the null indicator LED does not turn off, then the detector may need to be
calibrated. Refer to page 58 for calibration instructions.
Digital line guide: Position the sensor so that it is approximately centered over the
registration line or edge. Calibrate the sensor (refer to page 65 for calibration
instructions). When the sensor is calibrated and positioned correctly an indicator dot will
appear in the display under the line or edge you want to track.
MICRO 4000NET Web Guide Control System
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e) Press the EDGE A, EDGE B, or LINE button to select the sensor under test.
f) Press the AUTOMATIC button.
g) Slowly move the sensor left or right and observe how the guide reacts. The guide should
move the web so that it follows (or chases) the movement of the sensor.
Edge detector: The guide should move the web so that the edge of the web is always
aligned with the edge detector’s guide point.
Digital line guide: The guide should move the web so that the line or edge pattern is
always aligned with the line guide’s sight point.
Note: If the guide does not follow the movement of the sensor and moves in the opposite
direction, then the sensor polarity (parameters 3, 4, or 50) is not correct and must be
changed. Refer to page 17 for more information about setting controller parameters.
h) If the guide mechanism oscillates around the guide point or overshoots excessively when
steering in response to an abrupt change in web position, the servo gain (parameter 5) is
too high and must be lowered. Refer to page 17 for more information about setting
controller parameters.
MICRO 4000NET Web Guide Control System 9
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Operation
The MICRO 4000 NET may be configured for a wide variety of applications, but most
configurations share the same basic operating procedure:
1) Press the SERVO-CENTER button and wait for the web guide to drive to the center of travel.
2) Thread the web through the machine.
3) Position the sensors.
One edge detector: Place the detector near the edge of the web. Move the detector towards
the web until its null indicator LED turns off. Note: The scribed lines on the edge detector
indicate the approximate location of the detector’s guide point.
Two edge detectors (centerline guiding): Press the EDGE A button. Place detector A near
the edge of the web. Move detector A towards the web until its null indicator LED turns off.
Press the EDGE B button. Place detector B near the opposite edge of the web. Move
detector B towards the web until its null indicator LED turns off. Note: The scribed lines on
the edge detector indicate the approximate location of the detector’s guide point.
Digital line guide: Position the sensor so that it is approximately centered over the
registration line or edge. When it is positioned correctly an indicator dot will appear in the
display under the line or edge you want to track. Refer to page 60 for more information about
operating the line guide.
4) Press the EDGE A, EDGE B, or LINE button. For Centerline mode (centerline guiding), press
the EDGE A and EDGE B buttons simultaneously.
5) Press the AUTOMATIC button. The system will now guide the web.
Scribe mark Scribe marks
Null indicator Null indicator
Move detector until
null indicator turns off Web Web
PointSource detector WideArray detector
Centerline guiding with WideArray detectors
MICRO 4000NET Web Guide Control System
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Troubleshooting
The following checklist has been provided to assist in the analysis and repair of potential trouble
situations with the MICRO 4000 NET system. If a situation occurs that is not described in this list,
contact AccuWeb for assistance.
Problem Solution
The system will not work in Automatic, Manual, or Servo-
Center mode. Check items 1, 2, 3, 4, and 5 in the table below.
When the system is in Automatic mode, the web guide steers
the web in the wrong direction. Check item 6 in the table below.
The system oscillates in Automatic mode even though web is
not being pulled through the machine. Check items 7 and 8 in the table below.
The system is unstable in Automatic mode while pulling web. Check items 9, 10, 11, and 12
in the table below.
The actuator extends or retracts beyond the actuator’s end-of-
travel limits then jams. Check items 13, 14, 15, 16, 17, 18, and 19 in the table
below.
The web guide or actuator hits a mechanical stop before
reaching the actuator's end-of-travel limit. Check item 15 in the table below.
The system will not work in Automatic mode but works
correctly in Manual and Servo-Center mode. Check items 20, 21, and 22 in the table below.
While in Automatic mode the web guide or actuator moves too
fast or slow in response to large changes in the position of the
edge of the web (such as a splice).
Check item 23 in the table
below.
While in Manual mode the web guide or actuator moves too
fast or too slow. Check item 24 in the table below.
The numeric display is showing a flashing ‘99’ error code. If error code is ‘10’, then
check item 5 in the table
below, else refer to page 42
for more information about
error codes.
Item Description / Repair Procedure
AC power. If the LED data displays are not lit, check the AC power and
repair if not connected.
1
No output from the PWM motor drive. Connect a digital voltmeter to the
actuator motor leads at J5 terminals 1 and 2. Press the MANUAL button
and then press and hold the IN or OUT button. If there is no voltage but the
LED data displays are lit, the PWM motor output has failed and the system
must be returned for repair.
2
Actuator failure. If there is motor voltage present in the previous step but
the actuator does not move, the actuator motor or cable has failed.
Troubleshoot and repair as required, or return the equipment for repair.
3
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INHIBIT input polarity is set wrong. Set parameter 19 to the correct
value. Refer to page
4 17 for more information about setting controller
parameters.
5 New software was installed during routine maintenance.
or
Non-volatile memory contains invalid data or has malfunctioned.
Reset all parameters to their default values:
Caution: This procedure will erase all previously entered parameter
settings! Be sure to record all current settings on page 39 before
performing this step. If you are installing new software, then you must
record the current settings before installing the new microcontroller
chip.
1. Turn the AC power off.
2. Press and hold the EXIT button.
3. Turn the AC power on.
4. When the ‘reset’ message appears on the numeric display, release the
EXIT button.
5. Set parameter 2 (end-of-travel mode) and other parameters to their
previous values. Refer to page 17 for more information about setting
controller parameters.
Sensor polarity is wrong. The value of parameter 3, 4, or 50 must be
changed for the selected sensor. Refer to page
6 17 for more information
about setting controller parameters.
Servo gain is too high. Decrease the value of parameter 5. Refer to page7 17 for more information about setting controller parameters.
End play in the actuator or mounting. Press the MANUAL button and
then press IN and OUT buttons several times. Actuator operation should be
smooth and free, without binding. Firmly grasp the web guide mechanism
moving part and push and pull to check for end play. Observe the actuator,
mechanical components, and mounting hardware. There should be no
observable motion in the mechanical system. If motion is noted, repair the
web guide or actuator as required, or return the equipment for repair.
8
9 Sensor in wrong position.
Unwind stand: The sensor should be located down-web, close to the last
shifting idler roll. Refer to the guide application drawings on page 137.
Winder stand: The sensor should be located up-web before the last fixed
idler roll, one to two web widths from the shifting base. Refer to the guide
application drawings on page 137.
Intermediate guides: The sensor should be placed close to the exiting
idler roll. Refer to the guide application drawings on page 137.
Excessive chuck wobble. Decrease the web speed or re-chuck the roll of
material.
10
Web tension is low or tension control varies. Increase the web tension
or repair the tension control.
11
MICRO 4000NET Web Guide Control System
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Excessive web curl. If web flutter or curl exists, change parameters 6 and
18 to higher values. Refer to page
12 17 for more information about setting
controller parameters.
All actuators. End-of-travel mode is incorrect. Set parameter 2 to the
correct value. Refer to page
13 17 for more information about setting controller
parameters.
14 All actuators. Actuator cable wires are broken, shorted or connected
to wrong terminals of J5. Refer to the connection diagrams on page 137.
Check wiring at J5 and check the actuator cable for broken or shorted
wires.
15 Actuators with potentiometer feedback (MT, SF, HL, HF, HT, and UHT).
End-of-travel limits not set correctly. Parameters 9 and 10 must be
adjusted to stop the actuator before the web guide or actuator hits any
obstruction. Refer to page 17 for more information about setting controller
parameters.
16 Actuators with potentiometer feedback (MT, SF, HL, HF, HT, and UHT).
Potentiometer failure. Refer to the potentiometer replacement procedure
on page 86.
17 Actuators with limit switches (MM, MME, MN, and MNE). Limit switch
failure. Check the limit switch voltage at J5 terminals 5 and 6 (terminal 10
is GND). This voltage should normally be 0.0 VDC (switch is closed), then
jump to +5.0 VDC when the limit is reached (switch opens). If the correct
voltages are not present, replace the limit switch in the actuator or return
the actuator for repair.
Actuators with limit switches (MX). Limit switch failure. The end-of-
travel limit switches in the MX-series actuators directly control the motor
circuit and cannot be monitored externally. If a limit switch has failed,
replace the switch or return the actuator for repair.
18
Reversed motor wires. Restore the motor wire connections at J5
terminals 1 and 2 to the proper connection. Refer to the connection
diagrams on page
19
137. Change the value of parameters 3, 4, or 50 as
required. Refer to page 17 for more information about setting controller
parameters.
Edge detector not calibrated. Refer to page20 58 for calibration instructions.
Edge detector: transducers covered with dust or other material. Clean
the edge detector transducer face with a cloth dampened with water or a
mild detergent solution. If the contamination cannot be removed with this
method, return the edge detector for repair.
21
Digital line guide: optics covered with dust or other material. Clean the
underside of the sensor with a soft cloth dampened with water or a cleaning
solution suitable for photographic lenses. If the contamination cannot be
removed with this method, return the sensor for repair.
Edge detector failure. Observe the value of parameter 14 or 15 as
required. If this value is below 100, the edge detector is failing and must be
returned for repair. Refer to page
22
17 for more information about displaying
controller parameter settings.
Auto-mode speed limit setting is incorrect. Change the value of
parameter 7. Refer to page
23 17 for more information about setting controller
parameters.
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Manual-mode speed setting is incorrect. Change the value of parameter
8. Refer to page
24 17 for more information about setting controller
parameters.
MICRO 4000NET Web Guide Control System
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Appendix 1 / Motor Drive Calibration
Note: The PWM motor drive module is not easily accessible, however user adjustment is typically
not necessary and is not recommended.
PWM Motor Drive
The PWM motor drive converts the system command voltage into a drive voltage for the actuator
motor. The motor drive consists of a separate power supply and PWM servo amplifier. This servo
amplifier is run in voltage mode for highest response and accuracy. All adjustments are sealed
when the system is shipped and should not require adjustment. If adjustment is required, this is
easily accomplished using the following procedure:
Note: A digital voltmeter (DVM) with at least 2½ digit accuracy will be required during the
following procedure.
Adjustment Procedure:
1) Verify that the servo module is configured for voltage mode with the DIP switch set as
follows:
Switch Setting
1 ON
2 OFF
3 OFF
4 OFF
2) Put the system into Manual mode and drive the actuator to ensure that it is not at a limit.
3) Connect the DVM leads to terminals 13 and 14 (motor output).
4) Verify that the DVM reads between +1.00 and -1.00 volts. Adjust R4 (test--offset) on the
servo amplifier module if required.
5) Put the system into Automatic mode and verify that the system responds quickly to
position errors without oscillation.
6) If a whistling noise is heard from the servo amplifier module, adjust R3 (reference input
gain) CCW until it stops.
7) The other potentiometers are adjusted at the factory and do not require further
adjustment in the field. Do not attempt to adjust these potentiometers.
P2
P1
4321
DIP SW.
R4R3R2R1 12345
1
PWM Servo Amplifier
MICRO 4000NET Web Guide Control System 15
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MICRO 4000®NET Controller
MICRO 4000NET Controller
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Introduction
The MICRO 4000 NET controller’s main functions include polling the web sensors, end-of-travel
sensors, and control inputs, processing the input data, and sending the results to the servo-
amplifier and status outputs.
The controller’s main features include the following:
Compatible with all ultrasonic and infrared PointSource and WideArray edge detectors,
ultrasonic Hi-Temp edge detectors, and AccuBeam 3 digital line guide. These sensors are
described on pages 55 and 60.
Has a built-in parameter-entry keypad and display.
Has a variety of digital inputs and outputs that allow the customer’s PLC to control its
operating modes and monitor its status. These are described on pages 45, 46, and 48. In
addition, the controller can be connected to a wide variety of fieldbus networks by installing
an optional Fieldbus Interface card. This card is described on page 102.
Has several analog inputs and outputs that may be used for interfacing to voltage-output
sensors, PLCs and other MICRO 4000 NET controllers. A setup procedure for these ports is
described on page 50.
88 and 97.Compatible with the Remote Stations described on pages
Parameters
The MICRO 4000 NET system is configured by setting programmable parameters. These
parameters are stored in non-volatile memory and may be examined or changed by using the
parameter-entry keypad and display located on the MICRO 4000 NET board.
Note that the CODE and DATA display will show dashes immediately after power is turned on
and after the EXIT button is pressed. The dashes indicate that no parameter is currently selected
for examination or adjustment, but that the system is operating normally.
-- -----
CODE DATA
The general procedure for reading and/or changing the parameters is as follows:
1) Press the UP (▲) or DOWN (▼) CODE buttons to select the parameter you want to examine
and/or adjust. Each parameter has a unique code number.
2) Press the UP (▲) or DOWN (▼) DATA buttons to adjust the parameter’s setting.
3) Press ENTER to store the new data value in non-volatile memory. To leave the data value at
its original value press EXIT, or press the UP (▲) or DOWN (▼) CODE buttons.
The parameters are described below:
Software Version
1 x x. x x
This parameter displays the software version.
MICRO 4000NET Controller 17
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