Motrona FS150 User manual

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

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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:
FS15016N/ TJ/ Oct. 03/
Page/21/26/42
Max. 8 print marks between sensor and home position
Control word and status word
Encoder inputs levels and max. frequency
FS15016C_d/Bo/Jul-08
Modification to motrona format

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Table of Contents
1. Introduction................................................................................................................... 5
2. Principle of Operation ................................................................................................... 6
3. Hardware Configuration................................................................................................ 7
4. Wiring and Screening ................................................................................................... 9
4.1. Encoders ..............................................................................................................11
4.2. Analogue Output .................................................................................................13
4.3. Power Supply.......................................................................................................14
4.4. Parallel Interface (PI) ...........................................................................................14
5. Control IN / OUT Port (PI/PO)....................................................................................... 17
6. The Serial Port ............................................................................................................ 20
7. Register settings......................................................................................................... 22
8. How to operate the Keypad......................................................................................... 23
9. The Data IN –Menu ................................................................................................... 26
10. Setup Menu ................................................................................................................ 33
11. Adjust Menu ............................................................................................................... 35
12. Testprog –Menu ........................................................................................................ 35
13. The LED Display .......................................................................................................... 36
14. Remarks about Drives, Encoders, Cables, Installation ................................................. 37
15. Steps for commissioning............................................................................................. 39
16. Alarm States and Conditions....................................................................................... 46
17. Accuracy considerations ............................................................................................. 47
18. Which shortest length can we cut at a certain line speed? ......................................... 49
19. Which maximum line speed can we use with a certain cutting length ........................ 50
20. Which travelling distance does our carriage need?..................................................... 50
21. Auxiliary Register and Command Codes...................................................................... 51
22. General Master Reset and Erase of EEProm................................................................ 53
23. The BY 106-X Remote Thumbwheel Switch ................................................................ 54
24. Dimensions and Specifications ................................................................................... 55
25. Serial Code List........................................................................................................... 57
25.1. Parameter ............................................................................................................57
25.2. Inputs...................................................................................................................58
25.3. Variables..............................................................................................................59

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Compatibility Hint
Versions FS15014A and higher use some different control inputs and control
outputs and therefore are not fully hardware compatible to former versions!
You must modify a few connections at the PI/PO connector when replacing older version
against FS15014A or a higher version! See section 5.
The software has been upgraded and now includes
Batch counters for total quantity, waste quantity, total length
Registers for actual line speed, carriage speed, synchronizing error etc.
3 software limit switches to protect against carriage overshoot. No more proximity for
extreme carriage positions necessary.
Real acceleration settings instead of ramp times
Virtual master axis with adjustable simulation speed
Impulse output with scaling facility for material line
Correction register for easy compensation of slip of the measuring wheel
Enhanced setup tools in the OS30 operator software, including scope functions,
providing still easier commissioning procedures.
Improved S- shape profile for still higher cutting efficiency.

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1. Introduction
Flying shears are used for cutting applications, where endless material to be cut to length
cannot be stopped during the cutting process and the cut must be effected “on the fly“. The
mechanical construction provides a saw or shear system mounted on a carriage, that follows
the material with synchronous speed while cutting is in progress, and then returns to a home
position to wait for the next cut. See schematics on title page.
The FS flying shear control is based on a BY150 synchronizer system. The software has been
designed for the special requirements of flying shears under consideration of maximum
efficiency and accuracy at minimum stress for all mechanical parts.
Only a few registers must be set in order to adapt the controller to the mechanical and
electrical specifications of the shear system.
A small keypad with LCD provides easy setup, but also a disc with operator software OS3.2 is
included for easy PC setup of the controller.
All essential registers like cutting length, tool width etc. are also accessible by parallel
interface, providing easy setting by remote BCD thumbwheel switch or PLC parallel output.
The unit uses a closed 19“ steel cassette for maximum EMC protection. With option SM150,
the housing can also be mounted on DIN rails.

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2. Principle of Operation
The shear (or saw blade) is fixed on a carriage that can move forward and reverse under control
of a +/- 10V speed reference voltage of the carriage drive. Normally, a 4 quadrant DC or servo
drive is used. For lower requirements in performance, the FS150 unit can also control
1-quadrant AC drives using a positive speed reference signal and two outputs for
forward/reverse select.
The FS150 controller counts the length from the line encoder (feed roll or measuring wheel)
while the carriage is held in its rear home position.
Once the cutting position approaches, the carriage accelerates and synchronizes with the line.
A "Ready to cut" signal is generated in order to start the cutting process, while the shear moves
fully synchronous with the cutting position on the material. When the cut is completed, the
FS150 must receive a "cut complete" signal. This will cause a deceleration and a reversal of the
carriage until it has reached its home position again. All speed transitions occur with a smooth
sin² speed profile for absolutely careful treatment of screws and other mechanicals parts.
Cut
V
VL Line speed
Speed profile
t
Fig 1
The FS150 control continuously measures the line speed and calculates an anticipation value to
start the carriage before the cutting length is reached. Thus the shear will exactly match the
cutting position of the material upon completion of the acceleration ramp and no over swing or
oscillation will take place prior to the cut. This saves time and increases the cutting efficiency
of the shear system considerably.

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3. Hardware Configuration
As a master drive, mostly the motor of a feed roll is used. The "master" can also be a measuring
wheel equipped with an incremental encoder.
The encoder resolution should be at least 5 times higher than the maximum acceptable cutting
error.
Quadrature encoders (TTL-types A, /A, B, /B) must be used. Where you find you must use
HTL encoders (10 –30 V, A and B output), please apply our level converter type PU210 to
generate the proper RS422 signals required.
Digital feed forward technology needs a certain minimum frequency: At maximum line speed,
the master encoder frequency should be at least a few hundred Hertz. It is best to choose the
ppr numbers of line and carriage encoders in a way to produce frequencies in the same range.
It is necessary to adjust the slave to its maximum dynamic response (no internal ramps, no
integral control loop, high proportional gain etc.) because the FS150 will generate ramps to
which the drive must follow with no additional delay.
A signal must be available to indicate completion of a cut to the FS150 controller. All control
signals must be PNP (switching to positive) with a level of 18....30 volts DC. Fig. 2 shows the
block diagram of the unit.

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Carriage
Encoder
+/-10V
(or +10V)
Analogue-
output
Slave
Input
Master
Input
A, /A, B, /B A, /A, B, /B
Power
24VDC
RS232 Ready
Reverse
Length
Carriage Alarm
Home position
Gap coml.
Ready to cut
Parallel
Data Input
Reset
Jog forw.
Jog rev.
Read PI
Start Gap
Cut Completed
Store EEProm
Start/Stop
Immediate Cut
Lenght 1 / Length 2
Zero Position
Dec Counter
RS485
CAN
FS150
Control
Inputs
Communi-
cation
Ports Outputs
Measuring wheel
Line-
Encoder
PLC or
BCD switch
Bold printed connections
are “must”
Other connections
are “can”
Carriage drive
Forward
*)
Virtual line On
With 1 Q drives only*)
Fig 2
For safety reasons, we strictly recommend to limit the travelling range by
mechanical limit switches at both ends in order to avoid damage with carriage
overshoot upon failure of the electronic control system!

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4. Wiring and Screening
Serial RS232
(Sub-D-9- female)
Parallel Interface
(Sub-D-25- male)
Control IN/Out
(Sub-D-25- female)
Analogue Out
(Sub-D-9- female)
Carriage encoder
(Sub-D-9- male)
Line encoder
(Sub-D-9- male)
24VDC
Supply
CAN Bus
Master Reset
button
LED
bargraph
PE (Grounding screw)
Fig.3
For reasons of proper screening, it is a must to follow the subsequent
instructions.
Where you don’t exactly observe these grounding and screening rules, it is
almost for sure that you will have problems later!
a. The minus wire of the power supply must be connected to the grounding screw on the front
plate of the FS150 controller with a short wire of at least 0.75 mm².
On site of the power supply, the minus output must be earthed.
Where the wires between power unit and FS150 controllers are longer than e.g. 1 meter, it
is advisable to ground the front plate of the controller again by a separate wire, on the
shortest way possible.
+24V Fs150
Supplement short earthing
when power cable is long
Power Supply PE
Fig 4

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b. All screens on the controller side must be connected to the housing of the corresponding
Sub-D-connector. This is valid for encoder cables, analogue output and PI or PO lines.
Where you use Sub-D-connectors with a plastic housing, you must solder the screen to the
metallic frame of the connector.
At any time you must be sure the screen gets a proper contact to the front fascia of the unit
when connected to the controller.
Screen
Fig 5
c. When encoder cables are interrupted by terminal boxes or intermediate connectors on their
way from the controller to the encoder, you must connect the screen to the Minus wire of
the encoder supply there, but never to earth potential again!
to encoder Encoder cable to FS150
Minus of encoder supply
Screen
Tie Minus of encoder supply and screen together whereever you interrupt the
encoder cable by terminal or connectors.
Make sure the screen can never get any earth potential here!
Fig 6
d. When the cable arrives at the encoder site, the screen must again be connected to the
Minus wire of the encoder supply, but not at all grounded to earth. In general, there are two
types of encoder connections:
Make sure the screen of the cabels is
connected to the Minus supply of the
encoder, but does not touch the metallic
housing of the connector.
Shaft Encoder
Encoder with plug connector
Fig 7
Leave this screen fully unconnected
here to avoid illegal double-earthing!
(Screen is internally earthed to
the encoder housing).
from FS150
Shaft Encoder
Encoder with cable end
Connect screen to the Minus wire
of the encoder supply here.
Avoid any earth connection via
contact to housings ect.
Fig8