FMS CMGZ 622 User manual

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.

Operating Manual CMGZ 622
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Table of Contents
1Safety Instructions ....................................................................................4
1.1 Description conditions 4
1.2 List of safety instructions 4
2Definitions..................................................................................................5
3System Components..................................................................................6
4System Description....................................................................................7
4.1 Functional Description 7
4.2 Force Sensors 7
4.3 Electronic Unit CMGZ622 8
4.4 Power Amplifier and Brake 9
4.5 Drive and Motor 9
5Controller theory.....................................................................................10
5.1 Tension control loops 10
5.2 PID Controller 10
6Quick Installation Guide........................................................................11
7Dimensions...............................................................................................12
8Installation and Wiring ..........................................................................13
8.1 Mounting the Electronic Unit 13
8.2 Wiring Diagram CMGZ622 15
8.3 Mounting the Force Sensors 16
8.4 Mounting the brake amplifier or the drive unit 16
8.5 Mounting the distance sensor 17
9General Operation ..................................................................................18
9.1 View of the Operating Panel 18
9.2 Calibrating the Measuring Amplifier 20
9.3 Setup the PID Controller 22
9.4 Entering the Reference Value 22
9.5 Determination of the control parameters 22
9.6 Switching the control parameters 23
9.7 Automatic operation 24
9.8 Additional settings 25
10 Setup of an Unwind Brake Controller ..................................................27
10.1 Configuring the basic parameters 27
10.2 Inputting the holding torque 27
10.3 Setup of pilot control 28
11 Setup of an Unwind Drive Controller...................................................31
11.1 Configuring the basic parameters 31
11.2 Automatic Start Function 31
11.3 Setup of pilot control 31
12 Setup of a Winding Drive Controller....................................................32
12.1 Configuring the basic parameters 32
12.2 Automatic Start Function 32
12.3 Setup of pilot control 33

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12.4 Taper Function 33
13 Setup of a Line Drive Controller...........................................................34
13.1 Configuring the basic parameters 34
13.2 Setup of line speed overlay 34
14 Parametrization.......................................................................................36
14.1 Schematic Diagram of Parametrization 36
14.2 List of System Parameters 37
14.3 List of Parameters CMGZ622 37
14.4 Description of the System Parameters 40
14.5 Description of the Parameters CMGZ622 41
14.6 Service Mode 54
15 Serial Interface (RS232) .........................................................................57
16 PROFIBUS Hardware Interface Description.......................................58
16.1 Wiring of the PROFIBUS Data Cable 58
16.2 Setting the PROFIBUS Address 58
17 PROFIBUS Interface Description.........................................................59
17.1 GSD File 59
17.2 CMGZ622A DP Slave Functional Description 59
17.3 Initial Parameters 59
17.4 Configuration 60
17.5 Function Code 61
17.6 Error Code 61
18 Interface CAN-Bus..................................................................................62
19 Technical Reference................................................................................63
19.1 Additional Setting Elements 63
19.2 Setting Elements on the Extension Board 64
19.3 Jumper for the Analogue Inputs / Outputs 65
19.4 Technical Data 67
20 Trouble Shooting.....................................................................................68
20.1 General Trouble shooting 68
20.2 Unwind Brake Trouble shooting 70
20.3 Unwind Drive Trouble shooting 70
20.4 Winding Drive Trouble shooting 71
20.5 Line Drive Trouble shooting 71

Operating Manual CMGZ 622
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1Safety Instructions
1.1 Description conditions
High danger of health
injury or loss of life Risk of damage to machines Notice for proper function
Danger
This symbol refers to high
risk for persons to get health
injury or loss life. It has to be
followed strictly.
Caution
This symbol refers to risk
of heavy mecanical
damage. This warning has
to be followed absolutely.
Note
This symbol refers to an
important information
about proper use. If not
followed, malfunction can
be the result.
1.2 List of safety instructions
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.
Local installation regulations are to preserve safety of electrical equipment. They are
not taken into consideration in this operating manual. However, they have to be
followed strictly.
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.
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 opening the housing!
Wrong setting of the jumpers and solder bridges may cause malfunction of the
electronic unit or the total system! Setting of the solder bridges and jumpers must
be checked carefully prior to power on! Setting of the solder bridges should be
carried out by trained personnel only!
The Tension Controller has no built-in „Emergency Stop Function”. However he
can drive brakes with high kinetic energy and drive units with high performance.
Depending on the kind of possible malfunctions, full braking or complete release
may cause heavy damage of man and/or machine. The same applies also for drive
units. Therefore, the person responsible for system design has to establish a security
concept that is providing appropriate emergency procedures for the possible
malfunctions.

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2Definitions
Offset: Correction value for compensation of the zero point difference. Thanks to the
offset, it is ensured that a force of 0N will generate a signal of zero exactly.
Gain: Amplification factor for the measuring signal. Use of an appropriate value will
adjust the force sensor signal to the material tension feedback value exactly.
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.
Subprint: Electronic extension module which can be plugged in to the main board of
the electronic unit if required. That way, the possibilities of the electronic unit can be
extended easily.
Channel: The analogue inputs and outputs of a subprint, used for a certain purpose.
There can be up to four channels in a single electronic unit.
Module: The software running on the microprocessor is spread over various function
units (modules). A module can be used multiple times, i.e. when two measuring points
are operated, the module „measuring amplifier“ is used twice. Each module has its
own parameters and special functions.
Pilot control: If pilot control is activated, a reel diameter signal (from a distance
sensor, PLC or similar) is taken into the calculation of the drive power and the drive
will be „pilot controlled“ with the calculated value. Then, the controller has only to
control the variation of the material tension. Due to that, the stability of controlling
will be improved.
Single quadrant and four quadrant drive: Expression refers to the speed/torque
diagram used in the drive technology. A single quadrant drive can only drive in
forward direction; a four-quadrant drive can both drive and brake in forward and
reward direction.

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3System 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
•For supplying the force sensors and amplifying of the mV signal
•With integrated digital PID-controller
•Can operate unwind brake, unwind drive, winding drive or line drive
•Speed or torque control supported
•External diameter or line speed signal can be processed an added to the output
value
•Integrated brake amplifier
•With operation panel for parametrization
•With robust aluminium housing
•Supports connection of external feedback displays
•Interface RS232
•Interface CAN-Bus, PROFIBUS
•Internal brake power amplifier CMGZ.B to drive a brake
External brake power amplifier
•any suitable brake power amplifier to drive a brake
Brake
•any suitable electrical brake
•Pneumatic brake (when using electric/pneumatic converter)
Drive
•any suitable speed or torque controlled four quadrant drive
•AC or DC motor
(Components. variants or options indicated in italic text)

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4System 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. A digital input selects the
measuring range to be used for the control loop. If the material tension deviates too
much, the brake or the drive will be activated more ore less depending on
configuration.
4.2 Force Sensors
The force sensors are based on the flexion beam principle. The flexion is measured by
strain gauges and transmitted to the electronic unit as mV signal. Due to the
Wheatstone bridge wiring of the strain gauges, the measured value is depending also
to the power supply. So, the force sensors are supplied from the electronic unit by a
very accurate power supply.

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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. The electronic unit has no trimmers and only few jumpers to keep most accurate
long-time and temperature stability.
Operation
The large backlit display with 2x16 characters, 4 LED’s and large keys guarantee
simple operation. All information is in plain text with the following languages
selectable: English, German, French and Italian. Most of the functions may be
paramterized. The parametrization can be done via the keys or the interfaces. All
inputs are fail-safe stored in an EEPROM. Additional settings can be made with
jumpers or solder bridges.
Strain gauge amplifier
The strain gauge amplifier provides the highly accurate power supply (5VDC or
10VDC) for 1 or 2 force sensors per measuring point. The force sensors can be wired
using 4 wire circuit or 6 wire circuit. This allows accurate control of the bridge
excitation even with very long cabling.
The power supply is equipped with current control. This allows detecting of short
circuit or cables break automatically and to output an error message if required.
A highly accurate, fixed difference amplifier rises the mV signal up to 10V. This
signal will be fed to the A/D converter. The microprocessor then does all application
specific calculations with the digitized measuring value (such as offset, gain, lowpass
filter, limit switches, etc). The resulting feedback value is provided as both tension and
current signal at the same time.
PID Controller
The control unit compares the reference value with the measured feedback value and
transmits the error to the PID controller. The PID controller calculates the output
signal according to the difference. The output signal is 0...10V, ±10V, 0...20mA or
4...20mA, depending on configuration.
With a diameter sensor or other source, a 0...10V signal proportional to the actual reel
diameter can be fed to the controller. Driving a winder, the controller calculates the
pilot control resulting from this signal and the actual output value. The PID values are
adjusted dynamically according to the changing reel diameter.
With a tachometer generator or other source, a 0...10V signal proportional to the line
speed can be fed to the controller. Driving a line drive, the controller takes the line
speed signal as a base to which the PID signal is overlaid. Therefore the controller
must only control the deviation to the line speed.
Interface
(To be developed) As an option there are RS232, PROFIBUS or CAN-Bus interfaces
available.

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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. The power amplifier drives the brake corresponding to the output
signal of the electronic unit. Any power amplifier for brakes can be used.
Any electrical brake can be used or, when using an electric/pneumatic converter, any
pneumatic brake.
4.5 Drive and Motor
(Only if a drive is operated) There can be used any AC or DC four quadrant drive
suitable to the dynamics required and the motor used.

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5Controller theory
5.1 Tension control loops
When manufacturing and processing foils, wires, ropes, paper and fabric sheets, it is
important that the product is under constant tension when guided across the rollers.
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.
5.2 PID Controller
The function of any control loop is to
maintain the feedback value exactly at the
level of the reference and to minimize the
influence of any interference on the control
loop. In addition, the control loop must be
stable under all operating conditions.
These aims can only be achieved if the
dynamic behaviour of the control loop is
adapted to the machine.
The PID controller used in the FMS tension
control system calculates an output signal
that corresponds to the addition of „P“, „I“
and „D“ component. The „D“ component can
be skipped alternatively. Due to the digital
design, the controller has an exactly
reproducible behaviour, because every parameter is known as an exact number which
doesn’t drift away. Due to that, it has high long-time and temperature stability. This
feature also allows to exchange an electronic unit without readjusting.
„P“ component
A controller with only a proportional component gives an output signal that is
proportional to the error. If the error is zero, the output signal also will be zero. A
small error only can create a small output signal which is not high enough to compensate
the complete error. That means, that a controller with only a proportional component will
have a steady error. The characteristics of a. P-controller are the proportional factor Xp.
„I“ component
A controller with an integral component adds the error to the output signal
continuously and emits this output signal. Due to that, the output signal will be
enlarged or reduced until the error is zero. This output signal is maintained until a new
error occurs. The integral component therefore allows zero error in steady state. The
characteristic value of an „I“ controller is the settling time Tn.
„D“ component
A controller with a differential component has an output signal proportional to the
changing speed of the error. If the error changes in a step, the output will show the
characteristic peak impulse. Therefore, a „D“ controller reacts even if only a small
controller error occurs. The characteristic value of a „D“ controller is the derivative
action time TV.
fig 3: Step response of a PID
controller C432003e

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6Quick 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)?
– operating mode of the additional analog input (external reference, etc.)?
– controller output configuration (signal level)?
– feedback output configuration (signal level)?
– digital input / output assignment?
– linking by interface etc.?
– emergency stop procedures?
•Draw your final wiring diagram according to the wiring diagram (refer to „8.2
Wiring diagram“). Don’t forget the digital input „Controller enabled“
•Install and wire all your components (refer to „8. Installation and wiring“)
•Electronic unit: Parametrize and calibrate the measuring amplifier for each channel
(refer to „9. General Operation“)
•Proceed a test run with low speed and low material tension:
– Input reference value (ref. to „9.5 Inputting the reference value“)
– Enable controller (ref. to „9.8 Automatic operation“)
– Determine PID control parameters and set machine into operation (ref. to
„9.6 Determination of the control parameters“)
•If required, setup pilot control or line speed overlay (ref. to „10.3 Setup of pilot
control“ or „13.2 Setup of line speed overlay“)
•If required, do additional settings (refer to „9.9 Additional settings“
Note
It may be that the PID control parameters determined during the test run are no longer
suitable for stable operation after setup of pilot control or increasing of material
tension. Therefore it is useful to adjust the control parameters until the machine runs
stable at the required reference values.
Note
Starting and stopping of the machine takes increased requirements to any control loop.
For stable operating also in these phases, you have to pay special attention to the
starting and stopping behaviour of the whole machine. It is not enough to get stable
operating during normal operating conditions.

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7Dimensions
fig. 4: Dimensions C600005e
Type Housing size
CMGZ622 standard
CMGZ622.B big

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8Installation 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.
Caution
Local installation regulations are to preserve safety of electrical equipment. They are
not taken into consideration in this operating manual. However, they have to be
followed strictly.
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.
8.1 Mounting the Electronic Unit
The housing can be mounted in a control cabinet or directly beside the machine. All
connections are led into the housing through glands and are connected to the plug-in
screw terminals according to the wiring diagram (fig. 8 and 9).
fig. 5: Wiring path inside the housing E600002e

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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. 6: Screw terminal arrangement on the electronic unit E600003e
fig. 7: Screw terminal arrangement on the extension board and the brake
amplifier C600003e

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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

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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 4x2x0.75mm2[AWG 18] shielded twisted pair
cable. (With cable length below 15m, 4x2x0.25 mm2[AWG 23] is also suitable.) The
cable must be installed separate from power lines.
Wiring to the terminals of the electronic unit is done according to the wiring diagram.
If two force sensors are used per measuring point, the cables are wired parallel (ref. to
wiring diagram). If wiring is made using 6 wire circuit the solder bridges must be
modified (ref. to „9.2 Configuring the electronic unit“).
Force sensor excitation can be made using 5VDC (default) or 10VDC (ref. to
„9.2 Configuring the electronic unit“).
Note
The force sensor signal consists of only a few mV and is therefore susceptible to
external influences to the cable. To increase immunity to interfering use one pair of
the twisted pair cable for +signal and –signal.
Note
Connecting the shield of the signal cable to the electronic unit and to the force sensor
may cause ground circuits which may interfere the measuring signal massively.
Malfunction can be the result. The shield should be connected only to the electronic
unit. On the „force sensor side“, the shield should stay open.
8.4 Mounting the brake amplifier or the drive unit
The brake and brake amplifier or drive unit and motor will be mounted according to
manufacturer’s specification. Herein is no additional information written due to the
wide variety of suitable types. Wiring is done according to the wiring diagram.
If an AC drive unit is used, the energy produced in the motor while braking must be
led off to a brake resistor or equivalent.
Danger
The Tension Controller has no built-in „Emergency Stop-function. However he can
drive brakes with high kinetic energy and drive units with high performance.
Depending on the kind of possible malfunctions, full braking or complete release may
cause heavy damage of man and/or machine. The same applies also for drive units.
Therefore, the person responsible for system design has to establish a security concept
that is providing appropriate emergency procedures for the possible malfunctions.

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8.5 Mounting the distance sensor
If the control loop is operated with pilot control (processing of reel diameter), the
actual reel diameter has to be transmitted to the electronic unit. For this purpose the
actual reel diameter is detected with a distance sensor and the distance signal is fed to
the analogue diameter input. It has to be ensured that the measuring axis of the
distance sensor is straight radial to the reel (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. It is considerable
insensible to secondary light and changes of the surface colour of the detected object.
But while mounting it must be ensured that the sensor is mounted in „horizontal“
position (fig. 12). The output signal is proportional to the reel radius: Small radius =
small signal; large radius = large signal.
Technical data distance sensor CMGZ581934
Type HT77MGV80, Infrared light 880nm
Measuring range 1000mm [40“]
Ø Measuring distance 800mm [32“]
Min. measuring distance 300mm [12“]
Max. measuring distance 1300mm [51“]
Resolution 0.2...30mm [.008...1.2“] depending on width of spot
Reaction time 10ms
Linearity 2%
Temperature drift 0.5mm / K [.01“ / °F]
Supply voltage 18...30VDC / 70mA
Temperature range –10...+60°C [14...140°F]
Protection class IP67

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9General Operation
9.1 View of the Operating Panel
fig. 11: Operating panel CMGZ622 C622008e
fig. 12: Main operating menu CMGZ622 C622005e

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Configuring the Electronic Unit
The use of the input channels provided is as follows:
Input Channel assignment (ref. also to wiring diagram)
CMGZ622
Channel 1 Force Sensor, range 1 (low nominal force)
Channel 2 Force Sensor, range 2 (high nominal force)
Channel 3 External Reference / Diameter / Line Speed
Channel 4 –
Prior to the first calibration, the following settings must be done for each channel (ref.
to „14. Parametrization“ and „19. Technical reference“):
Jumpers for the analog outputs (ref. also to „19. Technical Reference)
CMGZ622
Channel 1 ±10V (using a drive) or 0...10V (using a brake)
Channel 2 0...10V (default)
Channel 3 –
Channel 4 –
System parameters
Language Required display language
Parameters CMGZ622
Nominal force 1 Low nominal force, ref. to nameplate of the force
sensor
Nominal force 2 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.
20mA?
Scale instrument 2 Which material tension feedback refers to 10V resp.
20mA?
These parameters are required to setup the measuring amplifier section of the
electronic unit. There are additional parameters required to setup the PID controller
section (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“)
Note
Wrong setting of the jumpers and parameters may cause malfunction of the electronic
unit! Setting of the parameters must be done carefully prior to setting into operation!

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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.
13).
The calibration procedure is written for
measuring range 1. It is valid analogous also
for measuring range 2. The commands for
measuring range 2 are writen in brackets.
Range 1: Make sure the digital input
„switch range“ is OFF (Range 2 = ON)
Check force sensors
•Connect the first force sensor (ref. to
wiring diagram).
•Check if a positive value is displayed
when loading the sensor in measuring
direction. If not, exchange terminals +signal and –signal on the measuring
amplifier.
•If used, connect the second force sensor.
•Check if a positive value is displayed when loading the sensor in measuring
direction. If not, exchange terminals +signal and –signal on the measuring
amplifier.
Find offset
•Insert material or a rope loosely to the machine.
•Press MODE key. Search and select the module Spec.F CMGZ622 1 and the special
function Find offset with the ↑↓↵keys (fig. 12).
•Find offset by pressing the ↵key for 3 seconds (fig. 12). The electronic unit
calculates automatically the new offset value. The display will return to the main
operating menu.
Find gain
•Load material or rope with a defined weight (fig. 13)
•Press MODE key. Search and select the module Spec.F CMGZ622 1 and the special
function Calibration with the ↑↓↵keys (fig. 12).
•Set the force referring to the applied weight into the display with the ↑↓keys and
confirm with ↵key (fig. 12). The electronic unit calculates automatically the new
gain value. The display will return to the main operating menu.
Repeat the calibration written above with the other measuring range.
fig. 13: Calibration measuring amplifier
C431011e