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.
!
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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
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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