ZF ERM User manual

Operating
instructions
6057 758 101b
ZF Electronic Control
Unit ERM

Subject to alterations in design
Copyright by ZF
The present documentation is protected by copyright.
Any kind of reproduction or dissemination in whatever
form that does not exclusively correspond to documen-
tation objectives will be prosecuted if no prior approval by
ZF Friedrichshafen AG was granted.
Printed in Germany
ZF Friedrichshafen AG, MC-C / 2001-03
Issue: 2005-02

Safety instructions
Companies repairing ZF units are responsible for their
own work safety.
To avoid injury to personnel and damage to products, all
safety regulations and legal requirements which apply to
repair and maintenance work must be adhered to.
Before starting work, mechanics must familiarize them-
selves with these regulations.
Personnel required to carry out repairs on ZF products
must receive appropriate training in advance. It is the
responsibility of each company to ensure that their repair
staff is properly trained.
The following safety instructions appear in this manual:
NOTE
Refers to special processes, techniques, data, use of
auxiliary equipment, etc.
CAUTION
This is used when incorrect, unprofessional working
practices could damage the product.
DANGER
This is used when lack of care could lead to personal
injury or death.
!
6057 758 101 - 2005-02 3

Read this manual carefully before starting any tests or
repair work.
CAUTION
Pictures, drawings and components do not always
represent the original object, but are used to illustrate
working procedures.
Pictures, drawings and components are not to scale.
Conclusions about size and weight should not be drawn
(even within a complete illustration). Always follow the
working steps as described in the text.
After completion of repair work and testing, skilled staff
must satisfy themselves that the product is functioning
correctly.
General Information
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1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Technical data, installation dimensions . . . . . . . 6
1.2 Circuit board removal and installation . . . . . . . . 8
1.3 Circuit board configuration . . . . . . . . . . . . . . . . . 10
1.4 Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Summary of pin assignment . . . . . . . . . . . . . . . . 14
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 General configuration . . . . . . . . . . . . . . . . . . . . . 16
2.2 Coding clutch / brake . . . . . . . . . . . . . . . . . . . . . 18
2.3 Controller for transfer function . . . . . . . . . . . . . . 19
3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1 Operating mode “open loop (current)” . . . . . . . . 20
3.1.1 Function diagram . . . . . . . . . . . . . . . . . . . 20
3.1.2 Pin assignment . . . . . . . . . . . . . . . . . . . . . 21
3.1.3 Technical instructions . . . . . . . . . . . . . . . . 22
3.1.4 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Operating mode “open loop (torque)” . . . . . . . . . 23
3.2.1 Function diagram . . . . . . . . . . . . . . . . . . . 23
3.2.2 Pin assignment . . . . . . . . . . . . . . . . . . . . . 24
3.2.3 Technical instructions . . . . . . . . . . . . . . . . 25
3.2.4 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Operating mode “controlled with Ø sensing” . . . 26
3.3.1 Function diagram . . . . . . . . . . . . . . . . . . . 26
3.3.2 Pin assignment . . . . . . . . . . . . . . . . . . . . . 27
3.3.3 Technical instructions . . . . . . . . . . . . . . . . 28
3.3.4 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4 Operating mode “controlled with Ø calculation” 30
3.4.1 Function diagram . . . . . . . . . . . . . . . . . . . 30
3.4.2 Pin assignment . . . . . . . . . . . . . . . . . . . . . 31
3.4.3 Technical instructions . . . . . . . . . . . . . . . . 32
3.4.4 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5 Operating mode “closed-loop control” . . . . . . . . 34
3.5.1 Function diagram . . . . . . . . . . . . . . . . . . . 34
3.5.2 Pin assignment . . . . . . . . . . . . . . . . . . . . . 35
3.5.3 Technical instructions . . . . . . . . . . . . . . . . 36
3.5.4 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.6 Additional functions max-power / zero-power . 37
4 Identification and causes of failure /
corrective action . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table of contents
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6057 758 101 - 2005-02 6
1 Technical data
1.1 Technical data, installation dimensions
Nominal direct voltage for ZF
hysteresis clutches and brakes at
nominal torque and a coil
temperature of 120 °C: 30 V DC
Permissible residual ripple: 1.5 V
Operating voltage range: 24 V to 36 V DC
Open circuit power consumption: < 150 mA
Maximum current input: 2.8 A
(depending on unit size)
Fuse: fine-wire fuse 4A
medium time-lag fuse
Voltage output: 10 V = +/– 0.8 V
20 mA
(Ra min = 500 Ω)
Frequency input: input resistance
RE≥3.3 kΩ
Switching threshold “low” to “high” > 11.5 V DC
Switching threshold “high” to “low” < 4.0 V DC
Ambient temperature: 0 to + 50 °C
Storage temperature: -30 to + 70 °C
Humidity class: DIN IEC 68, part 2-30
Safety class according
to DIN 40 050: IP 30
Rack: 19” 7 TE plug-in module
Connection: 18-pin pull-off screw-type
terminal (within the scope
of supply)
Weight: 0.6 kg
NOTE
The screw-type terminal block is not suitable for bus
assembly. Make sure that connecting cables are long
enough or that the screw-type terminal block on the
rear of the assembly rack is accessible.
Technical Data Electronic control unit ERM

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Electronic control unit ERM Technical Data
35
128
182.5
170
111.5
92
Installation dimensions
015242

1.2 Circuit board removal and installation
Removal:
1. Switch off operating voltage.
CAUTION
If the operating voltage is not switched off, product and
system can be damaged.
2. Remove terminal strip (2) from plug connector (3).
3. Remove screws (1 + 4).
4. Carefully pull board out of the rack without tilting.
Installation:
1. Carefully insert board into rack, guiding slot without
tilting.
2. Tighten screws (1 + 4) so that the cooling attachment
on the board contacts the metal rack and thus ensures
optimum heat dissipation.
NOTE
Do not exceed permissible tightening torque to avoid
board damage.
3. Make sure that operating voltage is switched off.
CAUTION
If the operating voltage is not switched off, product and
system can be damaged.
4. Introduce terminal strip (2) into plug connector (3).
CAUTION
Contacts must not be damaged, otherwise perfect func-
tioning of the system is not ensured.
Technical Data Electronic control unit ERM
6057 758 101 - 2005-02 8

Electronic control unit ERM Technical Data
6057 758 101 - 2005-02 9
1
2
3
4
015239

Technical Data Electronic control unit ERM
6057 758 101 - 2005-02 10
1.3 Circuit board configuration
Designation Function
LED (1)
“Power” Supply voltage is applied and ERM program is ready.
LED (2)
“Feedb.” Closed-loop control operating mode, i.e. DIL switch position 5 and 6 = “1”.
LED (3) • Ø sensing operation, DIL switch position 5 = “1” and 6 = “0” or
“Ø-Contr.” • Ø calculation operation, DIL switch position 5 = “0” and 6 = “1”.
• LED “Ø-Contr.” flashes, if the setting procedure has not been carried
out in the operating mode Ø calculation or Ø sensing.
Connection for Diagnostic connector for ZF MOBiDIG tester
diagnostic unit K-cable, acc. to ISO 9141
Jumper For function selection. e.g. feed rate interruption, emergency brake
Fuse Fine-wire fuse 4 A, medium time-lag fuse
DIL switches Setting of various operating modes and unit sizes
Program memory Includes microprocessor operating program
Data memory Contains operating parameters
Terminal strip 18-pin

Electronic control unit ERM Technical Data
6057 758 101 - 2005-02 11
1 2 3
OPEN
4 5 6 7 8
017182
Program memory
1
2
3
Jumper Data memory E2PROM Terminal stripMicroprocessorConnection for diagnostic unit
DIL switches Cooling attachement Fuse

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1.4 Pin assignment
Technical Data Electronic control unit ERM
OPEN
12345678
PNP
Stop Set
PNP
fv
fn
10 k 10 k
11
17 18
10
12
13
7
9
5
8
12
6
1
2
3
Jumper
14 15
14 15
16
7
9
5
8
+
–
+24 V to +36 V
Soll
Ist
015241
Example for external
analog input, e.g. SPS
Alternative function
Web tear recognition
PIN 17, 18 (+24 V to +36 V)

6057 758 101 - 2005-02 13
NOTE
The electronic control unit does not require the potentiometer to
fulfill any particular requirements. However, mechanical require-
ments regarding installation need to be considered.
Recommendations for potentiometer:
Resistance value: 1 kΩ- 47 kΩ
Type: magnetoresistive potentiometer, for voltage
input nom. value also wire potentiometer
can be used.
Jumper-Position:
Appropriate function is activated by inserting a jumper.
NOTE
Pos. 1 and 2 must never be connected simultaneously.
Electronic control unit ERM Technical Data
as supplied: standard functions,
tear recognition, friction compensation
terminal 14: current zero function;
terminal 15; current max. function
terminal 8: Ø actual 0 - 5 V, instead of 0 - 10 V
●●
●●
●●
1
2
3

1.5 Summary of pin assignment
PIN Function
1 ground (–)
2 ground (–)
3 no assignment
4 no assignment
5 analog ground
6 current return cable (measurement input)
clutch / brake max. 2.55 A
(depending on unit size)
7 voltage output 10 V ± 0.8 V DC
max. load 20 mA;
load impedance Ra min = 500 Ω
8 voltage input, actual value (0 to +10 V)
input resistance Ri= 200 kΩ;
Input may also be supplied by external analog
sources, provided the voltage refers to ground
(PIN 5) and the max. value does not exceed
+10 V.
PIN Function
9 voltage input, nominal value (0 to +10 V)
input resistance Ri= 200 kΩ;
Input may also be supplied by external analog
sources, provided the voltage refers to ground
(PIN 5) and the max. value does not exceed
+10 V.
10 digital input “stop”
input resistance 4.7 kΩ;
input current 5 to 8 mA;*
Umax = operating voltage
Function is maintained as long as the signal is
on.
11 digital input “set” (push-button)
input resistance 4.7 kΩ;
input current 5 to 8 mA;*
Umax = operating voltage
12 frequency input - fn(roller speed)
frequency 3 to 1000 Hz;
input resistance 3.3 kΩ
pulse ≥0.5 ms, interpulse period ≥0.5 ms
input resistance 3.3 kΩ
Technical Data Electronic control unit ERM
6057 758 101 - 2005-02 14

PIN Function
13 frequency input - fv(feedrate)
frequency 3 to 1000 Hz;
input resistance 3.3 kΩ
pulse ≥0.5 ms, interpulse period ≥0.5 ms
input resistance 3.3 kΩ
14 output roller speed
output voltage 24 V DC;
max. load 50 mA;
max. load impedance 10 kΩ;
A suppressor diode must be used with inductive
load (no varistor!)
input current - zero
load current 1 to 2 mA;*
For functions consult relevant operation mode.
Function is maintained as long as the signal is on.
15 output feedrate
output voltage 24 V DC;
max. load 50 mA;
max. load impedance 10 kΩ;
A suppressor diode must be used with inductive
load (no varistor!)
input current - max.
load current 1 to 2 mA;*
For functions consult relevant operation mode.
Function is maintained as long as the signal is on.
PIN Function
16 current output clutch / brake
max. 2.55 A (depending on unit size)
NOTE: Limit for EBU 2000!
17 voltage supply + 24 V to + 36 V
max. current 2.8 A (depending on unit size)
18 voltage supply + 24 V to + 36 V
max. current 2.8 A (depending on unit size)
* NOTE
Gold-plated contacts are recommended for pushbutton,
switch and relais.
Electronic control unit ERM Technical Data
6057 758 101 - 2005-02 15

2 Description
2.1 General configuration
The ZF electronic control unit ERM can control ZF
hysteresis clutches and brakes in different operating
modes, as required by the application.
The ERM is controlled by a microprocessor and features
programming, operation and diagnosis interfaces.
The ERM is designed for optimum supply of the ZF
hysteresis clutches EKU and the ZF hysteresis brakes
EBU. Controlled operating modes with size coding are less
suitable for performance optimized brake range.
The DIL switches enable the following operating modes
to be set:
• Operating mode: “open-loop control (current)”
This operating mode is set by the manufacturer, i.e. it
is not necessary to change the DIL switch positions.
Current is set and kept constant in accordance with
the nominal value input.
• Operating mode “open-loop control (torque)”
The DIL switches must be set to suit unit size
(Y Y Y Y) (see page 18).
Torque is set and kept constant in accordance with the
nominal value input.
Hereby, the interdependence of the nominal voltage
value/torque is subject to approximate linear distribution.
• Operating mode “controlled with Ø sensing”
The DIL switches must be set to suit unit size
(Y Y Y Y) (see page 18).
Setting procedure:
•sense maximum roller Ø
•push set key
•release set key
(reference value for max. Ø is accepted).
NOTE
Data are stored in non-volatile memory; data are not
erased when the supply voltage is switched off.
Description Electronic control unit ERM
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Operating mode “open-loop control (current)”
12345678DILswitch
00000000assupplied
Operating mode “open-loop control (torque)”
12345678DILswitch
YYYY00 . .Unit size - coding (characteristic)

The reference value for the max. Ø is not erased when the
supply voltage is switched off. It can therefore be used
when the ERM is fitted, i.e. it can be stored in E2PROM.
The stored reference value is deleted when another opera-
ting mode is selected (“open-loop control” or “closed loop
control”).
Production speed and nominal traction may be altered
even during operation.
• Operating mode: “controlled with Ø calculation”
The DIL switches must be set to suit unit size
(Y Y Y Y) (see page 18).
Setting procedure:
•approach maximum roller Ø
•push set key when production speed is reached
NOTE
If a frequency < 3 Hz is already reached during a setting
procedure, no reference values will be transferred (LED 3
continues flashing). Frequency range 3 - 1000 Hz.
Stored reference values are deleted when another opera-
ting mode is selected (“open-loop control” or “closed loop
control”).
•release set key (reference values for max. Ø is
accepted).
Production speed and nominal traction may be altered
even during operation.
Electronic control unit ERM Description
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Operating mode “controlled with Ø sensing”
12345678DILswitch
YYYY10 . .Unit size - coding (characteristic)
Operating mode “controlled with Ø calculation”
12345678DILswitch
YYYY01 . .Unit size - coding (characteristic)

• Operating mode “closed-loop control”
The DIL switches must be set to suit unit size
(Y Y Y Y) (see page 18).
PD, PI and PID are available for position-and-force
closed-loop control.
The I portion can be blocked by stop input. Thus, the
last controlled torque is maintained when the unit is
stopped.
2.2 Coding clutch / brake
NOTE
With DIL switches 1-4, the ERM control unit can be set to
the corresponding clutch or brake.
Coding Type nomi- nomi-
DIL switch nal nal
current torque
12 345678 [A] [ Nm]
1 0 0 0 EKU 0.3 0.9 0.4
0 1 0 0 EKU 1 1.3 1.0
1 1 0 0 EKU 3 1.5 3.0
0 0 1 0 EKU 10 1.8 12.0
1 0 1 0 EBU 0.1 0.4 0.15
0 1 1 0 EBU 0,3 0.75 0.4
1 1 1 0 EBU 1 1.25 1.1
0 0 0 1 EBU 3 1.25 3.3
1 0 0 1 EBU 10 1.5 12.0
0 1 0 1 EBU 30 2.2 39.0
1 0 0 1 EBU 60 G 1.5 82.0
0 1 0 1 EBU 200 G 2.2 268.0
1 1 0 1 EBU 250/1 1.1 0.6
0 0 1 1 EBU 500/3 1.4 2.5
1 0 1 1 EBU 1000/10 1.9 9.0
0 1 1 1 EBU 2000/30 2.7 26.0
0 0 1 1 EBU 500/30G 1.4 25.0
1 0 1 1 EBU 1000/100G 1.9 90.0
0 1 1 1 EBU 2000/300G 2.7 260.0
0 1 1 1 EBU 2000/600G 2.7 520.0
Description Electronic control unit ERM
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Operating mode “closed-loop control”
12345678DIL switch
YYYY1100PDforposition control
YYYY1110PIforforcecontrol
e.g. with mech. compensator
YYYY1111PIforforcecontrol
e.g. with no-travel tension sensor or freely
programmable
YYYY1101PID for position or force control

2.3 Controller for transfer function
PD for position control
PI for force control
e.g. mech. compensator
PI for force control
e.g. no-travel tension sensor
PID for position or
force control
Electronic control unit ERM Description
6057 758 101 - 2005-02 19
Coding
DIL switch
12345678
00
Coding
DIL switch
12345678
10
Coding
DIL switch
12345678
11
Coding
DIL switch
12345678
01
017601

3 Operating modes
3.1 Operating mode “open-loop (current)”
3.1.1 Function diagram
Operating modes Electronic control unit ERM
6057 758 101 - 2005-02 20
,
015234 015236
ZF Hysteresis brake
Tensile force F (N)
Roller
Current I (A)
ZF electronic control unit
Feed rate v (m/s)
Nominal
traction
2.55 A
Nominal 10 V
traction
current
characteristic