Motrona CT340 User manual

CT34002a_e.doc / Nov-15 Page 1 / 42
CT340 and CT641
High Performance Low Cost Controller
for Rotating Cutters and Printing Rolls
Precision controller for Rotating Cutters and Printing Rolls
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
Most compact unit including operator panel for direct access and
RS232 interface for remote access
PROFIBUS DP interface available (option)
Operating Instructions

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Safety Instructions
This manual is an essential part of the unit and contains important hints about function,
correct handling and commissioning. Non-observance can result in damage to the unit
or the machine or even in injury to persons using the
equipment!
The unit must only be installed, connected and activated by a qualified electrician
It is a must to observe all general and also all country-specific and application-specific
safety standards
When this unit is used with applications where failure or maloperation could cause
damage to a machine or hazard to the operating staff, it is indispensable to meet
effective precautions in order to avoid such consequences
Regarding installation, wiring, environmental conditions, screening of cables and
earthing, you must follow the general standards of industrial automation industry
- Errors and omissions excepted –
Version:
Description:
CT34001a / July 12 / TJ
First edition
CT34002a / March 15 / TJ
New parameter F03.029 … 031, new master speed display

CT34002a_e.doc / Nov-15 Page 3 / 42
Table of Contents
1. Available Models.......................................................................................................... 4
2. Introduction................................................................................................................... 5
3. Electrical Connections................................................................................................... 6
3.1. Power Supply ...................................................................................................................8
3.2. Auxiliary Outputs for Encoder Supply..............................................................................8
3.3. Impulse Inputs for Incremental Encoders ........................................................................8
3.4. Control Inputs Cont.1 –Cont.4 ........................................................................................9
3.5. Switching Outputs K1 –K4..............................................................................................9
3.6. Serial Interface ................................................................................................................9
3.7. Analogue Outputs ............................................................................................................9
4. Functional description................................................................................................. 10
4.1. Principle of operation.....................................................................................................10
4.2. System Configuration ....................................................................................................11
5. Keypad Operation ....................................................................................................... 12
5.1. Normal Operation ..........................................................................................................12
5.2. General Setup Procedure...............................................................................................12
5.3. Direct Fast Access to Cutting Length Setting ...............................................................13
5.4. Change of Parameter Values on the Numeric Level .....................................................14
5.5. Code Protection against Unauthorized Keypad Access ................................................15
5.6. Return from the Programming Levels and Time-Out Function ......................................15
5.7. Reset all Parameters to Factory Default Values ...........................................................15
6. Menu Structure and Description of Parameters .......................................................... 16
6.1. Summary of the Menu ...................................................................................................16
6.2. Description of the Parameters.......................................................................................18
7. Description of Commands and Outputs ....................................................................... 29
7.1. Commands .....................................................................................................................29
7.2. Outputs...........................................................................................................................31
7.3. Display of Actual Values................................................................................................32
7.4. Error Messages..............................................................................................................33
8. Steps for Commissioning ............................................................................................ 34
8.1. Running the Adjust menu ..............................................................................................35
8.2. Set Directions of Rotation .............................................................................................36
8.3. Tuning the Analogue Output..........................................................................................36
8.4. Setting of the Proportional Gain....................................................................................37
8.5. Tuning the controller......................................................................................................37
9. Appendix for model CT 641 ......................................................................................... 39
9.1. Relay Outputs.................................................................................................................39
9.2. Front Thumbwheel Switches .........................................................................................39
10. Specifications and Dimensions ................................................................................... 40

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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.
CT340:
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)
CT641:
Front size 96 x 96 mm (3.780’’ x 3.780’’)
Cutting length setting by keypad
or by front thumbwheel switches
Analogue output 14 bits
4 power transistor outputs (alert)
and 4 relay outputs (alert)
Both models are suitable for front panel or operator desk mounting, by means of the included
mounting clamps.
Where you desire to mount the units on DIN rails inside a cabinet, please refer to the mounting
brackets type SM 300 and SM 600 available as accessories.
Figure: SM300 mounting bracket for DIN rail mounting of CT340 units

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2. Introduction
The CT340 / CT641 units are suitable for control of rotating cutter systems, partial printing
screens and rotating punching or sealing applications.
The CT340 / CT641 units have been designed for the special requirements of these rotating
systems, under consideration of maximum efficiency and accuracy, with minimum stress for all
mechanical parts. Very short control cycles together with intelligent motion profiles provide
excellent performance under all operating conditions.
The units are very easy to set up. All settings can be made either by keypad and display at the
unit or by PC, with use of the motrona operator software OS3.2.
All relevant operational parameters and variables are accessible by RS232/RS485 interface. For
PROFIBUS applications, our PB251 gateway is available. Therefore the user has multiple
possibilities for remote control of all batch and cutting parameters via operator terminals, PC or
PLC systems.
The units are suitable for control of cutting applications as well as for partial printing screens
and rotating punching or sealing applications. This manual always says “cutting“ or “cut“ and
the reader may replace this by “printing“, “punching” or “sealing” when applicable.
This manual first provides all basic instructions for operation of model CT340
For operation of relays and thumbwheels with model CT 641 see appendix
For PC setup our “OS32” software is available on the CD included to delivery,
or on our homepage www.motrona.com
For communication by PLC or IPC or by a remote operator terminal, please
observe the serial protocol details described in our separate manual “Serpro”.
PROFIBUS communication is possible with use of our gateway PB251.

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3. Electrical Connections
17 18 19 20 21 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
GND
GND
GND
GND
GND
+Vin
+5,2V aux.out +5,2V aux. out
+24V aux.out +24V aux. out
Slave, B
Slave, A
Master, B
Master, A Master, /A
Master, /B
Slave, /A
Slave, /B
K2 out
K1 out K3 out
K4 out
Cont. 1
Cont. 2 Cont. 4
Cont. 3
Com+ (K1-K4)
TxD (RS232)
Ana.out +/-10V
Ana.out 20 mA
RxD (RS232)
PROG
X1
X2
+5
-
A
/A
B
/B
+5
-
A
/A
B
/B
Cont1
Cont2
Cont3
Cont4
Reset, Start,
Immediate Cut,
Cutting Pulse
etc.
RxD
TxD
GND
RS232
-
+24 V DC
Power supply
Com+ (K1 - K4)
K1 out
K2 out
K3 out
K4 out
+24
+24
+/-10V
20 mA
0V, GND
PROG
18
24
23
20
19
22
21
11
12
6
5
27
28
30
3
31 17 1
4
29
26
25
7
8
32
2
16
15
14
13
10
9
  24 V AC
Example shows wiring
for encoders with
5 V power supply and
RS422 line driver output
Speed setpoint
Speed setpoint
Analogue
output
Error
Alarm
Automatic
Operation
Homing Done
Cutting roll
drive

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Terminal
Name
Function
01
GND
Common Ground Potential (0V)
02
+5,2V out
Aux. output 5.2V/150 mA for encoder supply
03
+24V out
Aux. output 24V/120 mA for encoder supply
04
GND
Common Ground Potential (0V)
05
Slave, /B
Cutting roll encoder, channel /B (B inverted)
06
Slave, /A
Cutting roll encoder, channel /A (A inverted)
07
Master, /B
Line encoder, channel /B (B inverted)
08
Master, /A
Line encoder, channel /A (A inverted)
09
K4 out
Digital output K4, transistor PNP 30 volts, 350 mA
10
K3 out
Digital output K3, transistor PNP 30 volts, 350 mA
11
Cont.4
Programmable control input
12
Cont.3
Programmable control input
13
(PROG)
(for download of new firmware only, not for general use)
14
RxD
Serial RS232 interface, input (Receive Data)
15
Ana.out 20 mA
Analogue output 0 –20 mA (Slave speed reference) **)
16
Ana.out +/-10V
Analogue output -10V … 0 … +10V (Slave speed reference) **)
17
+Vin
Power supply input, +17 –40 VDC or 24 VAC
18
+5,2V out
Aux. output 5,2V/150 mA for encoder supply
19
+24V out
Aux. output 24V/120 mA for encoder supply
20
GND
Common Ground Potential (0V)
21
Slave, B
Cutting roll encoder, channel B (non-inverted)
22
Slave, A
Cutting roll encoder, channel A (non-inverted)
23
Master, B
Line encoder, channel B (non-inverted)
24
Master, A
Line encoder, channel A (non-inverted)
25
K2 out
Digital output K2, transistor PNP 30 volts, 350 mA
26
K1 out
Digital output K1, transistor PNP 30 volts, 350 mA
27
Cont.2
Programmable control input
28
Cont.1
Programmable control input
29
Com+ (K1-K4)
Common positive input for transistor outputs K1-K4
30
TxD
Serial RS232 interface, output (Transmit Data)
31
GND
Common Ground Potential (0V)
32
GND
Common Ground Potential (0V) for DC or AC power supply
*) 120 mA and 150 mA are per encoder, i.e. total maximum currents are 240 mA and 300 mA
**) In general, the voltage output terminal 16 should be used for the slave speed signal

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3.1. Power Supply
The CT340 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).
Terminals 3 and 19 provide an auxiliary output with approx. +24 volts DC (240 mA totally)
3.3. Impulse Inputs for Incremental Encoders
All input characteristics of the impulse inputs can be set by the parameter menu, for each of
the encoders separately. The unit works with quadrature information (A / B, 90°) only. In theory,
any of the following encoder characteristics would be applicable:
Symmetric differential signals according to RS422 standard, however 1V min. as
differential voltage.
TTL inputs at a level of 3.0 to 5 volts (differential, with inverted signal)
TTL inputs at a level of 3.0 to 5 volts (single-ended) *)
HTL signals at a 10 –30 volts level
(alternatively differential A, /A, B, /B, or single-ended A, B only)
Impulses from photocells or proximity switches etc. providing a HTL level (10 –30 volts)
Proximity switches according to NAMUR (2-wire) standard
(may need additional remote resistor)
*) requires special settings of the threshold parameters, see “Special parameters F08”
For trouble-free operation it is mandatory to use quadrature encoders with
channels A and B or with channels A, /A, and B, /B (90° phase displacement).
Where the impulse level is HTL (10 –30 volts) you can use either single-
ended signals (A and B only) or differential signals (A, /A, B, /B)
Where the impulse level is TTL or RS422, it is strictly recommended to use
symmetric differential signals (with inverted channels /A and /B).
Under industrial environment conditions, single-ended TTL signals may cause
serious problems due to insufficient EMC immunity of the signal lines
All encoder input lines are internally terminated by pull-down resistors (8.5
kΩ). Where encoders with pure NPN outputs are used, corresponding pull-up
resistors must be available inside the encoder or externally to ensure proper
function (1 kΩ... 3.3 kΩ).

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3.4. Control Inputs Cont.1 –Cont.4
These inputs can be configured for remote functions like Reset, Start, Cutting Pulse, 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.
For reliable operation of the Control Inputs a minimum impulse duration of
50 µs must be ensured. Especially when using the Z marker pulse of a HTL
encoder as cutting pulse, please verify that this minimum duration can be kept
even with maximum speed of the machine
3.5. Switching Outputs K1 –K4
CT340 provides four digital outputs to signal control states like Homing Done, Alarm or Error.
K1 –K4 are fast-switching and short-circuit-proof transistor outputs with a switching capability
of 5 –30 volts / 350 mA each. The switching voltage of the outputs must be applied remotely
to the Com+ input (terminal 29)
3.6. Serial Interface
The serial RS232 interface can be used for the following purposes:
Set-up of the unit by PC with use of the OS32 PC software
Remote change of parameters during operation
Remote readout of actual values by PLC or PC
The figure below explains the connection between the CT340 unit and a PC using the standard
Sub-D-9 serial connector
2
3
5
RxD
TxD
GND
screen
PC
CT 340 14
(Sub-D-9)
30
31
TxD
RxD
For details of the serial communication protocol, please refer to the special “Serpro” manual.
3.7. Analogue Outputs
The unit provides a voltage output of +/- 10 volts (load = 3 mA), and a current output of
0 –20 mA (load = 0 –270 Ohms), both at a resolution of 14 bits (13 bits + sign).
With most standard applications the voltage output is used as a speed reference signal,
connected to the speed input of the cutting roll drive.

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4. Functional description
4.1. Principle of operation
When a cutting process needs synchronous circumferential speed of the cutting tool with the
line, the only length that can be cut is the one corresponding to the circumference of the cutting
roll (at constant rotational speed). Change of the cutting length needs exchange of the cutting
roll against another one with appropriate diameter.
The CT340 and CT641 controllers use a two-speed principle featuring full synchronism while
the cut is in progress, but taking a different roll speed when the tool is outside the cutting zone
(where synchronism is not necessary). So, in terms of one revolution of the roll, we are talking
about two speed zones: The “synchronous cutting zone“ (which is register settable) and the
“asynchronous zone“ where the roll follows a speed profile calculated in order to get the
desired cutting length. The speed profile of the “asynchronous zone“ is calculated in a way that
the physically possible minimum of acceleration and deceleration torque is applied to the drive
with respect to actual line speed and preset cutting length.
All speed transitions use self-optimizing S-shape profiles for minimum wear and tear of all
mechanical parts, unless a linear ramp form has specifically been selected by corresponding
parameter setting.
With length settings smaller than the roll circumference, the “asynchronous zone” will take
higher speeds than the “synchronous zone”. With length settings longer than the
circumference, the asynchronous speed will be lower and the drive can even go to a temporary
standstill if necessary. The figure below shows two typical speed profiles:
Cut
V
Line
Sync Zone
t
Cut
V
Line Sync Zone
t
Continuous closed loop control of the relative roll position with respect to the length progress
of the line, combined with a short update time provide best cutting accuracy and exceptional
smooth motion of the cutting roll at any time.
It is a must to use a 4-quadrant drive or a servo drive for the cutting roll, because the CT340 /
CT641 must be able to accelerate and decelerate the roll under real closed loop conditions.
However, no special requirements are necessary for the line drive for full performance.