The CX-1102 motion controller is used with various types of motor drives for precision control of unwind/
wind applications. The typical application consists of a web or line coming off of a powered unwind roll,
passing through a dancer loop and being taken up on a powered rewind roll. Both axis must have quadrature
(bidirectional) encoders either on the motor shaft or on the roll shaft. Generally both of the axis will be under
control of the CX-1102. It is possible, however , that one of these rolls will be under external control.
This guide is intended to assist with the start up of elementary unwind/wind systems. More involved
applications should be implemented only after the system is working as herein described. Refer to the CX-1 102 Technical ReferenceManual for a comprehensive and detailed explanation of the CX-1102’s features
and operations.
The CX-1102 start-up procedure consists of:
•Basic Wiring
•Operator Interface Primer
•System Setup Procedure
The following assumptions are made:
•Except for the changes required here, the CX-1102, including its PLC, will be programmed as factory
default.
•The default tuning for the CX-1102 should be stable for most applications and will not be discussed
here.
•Quadrature sensors are required for all applications.
This information is useful (but not essential) to complete setup.
•Dancer Mechanical Design: The Dancer content is the length of web material stored in the dancer
between its empty and full positions. This storage must be at least equal to 0.5 seconds of web travel at
maximum Line Speed. The nominal operating point, or Dancer Setpoint, should position the dancer at
approximately mid-range between empty and full.
The length and angle of the dancer arm should result in a near linear relationship of dancer position vs
dancer content. Avoid high angles of dancer rotation, or severe angles of web entry or web exit paths.
The web tension is determined by the loading on the dancer arm, either by deadweight, or by
pneumatic cylinder. The CX-1102 attempts to maintain dancer position, and does not directly control
web tension.
Page 1
•Dancer Electrical Design: The analog electrical signal from the dancer should be stable, repeatable,
noise-free, and linear with respect to dancer movement. It can be a potentiometer, or some non-contact
analog sensor. Sonar or ultrasound detectors on a free loop web may not be acceptable due to
instability or low resolution.
The electrical signal does not necessarily have to traverse the entire 0 to 5 vdc range over the dancer
range of physical motion. It must traverse at least a 1 volt minimum electrical range, and more voltage
swing would improve resolution and accuracy of calculations.
•Axle vs Surface encoders: Axle encoders are simpler to install, and usually have a more rugged
mounting location.
Surface traction-wheel or idler- roll mounted encoders may yield more accurate surface speeds, but are
more cumbersome to mount. Web-breaks, or web slippage can cause undesirable results.
•Use of Traction-Wheel or Idler-Roll encoders: Choose “Fixed Diameter” configuration option, just
as though that axis is a fixed nip-roll design. A Traction-Wheel with a 1-foot circumference is entered
as a 3.82 inch diameter roll. (12 inch/π)
•Roll RPM vs Motor RPM: The CX-1102 never asks how fast the motor can go. RPM always refers
to the speed of the roll axle. Please study the mechanical design of the machine to understand the gear
reduction between motor, encoder and roll axle. Only the top axle RPM, and the Gear Reduction from
encoder to axle are parameter entries in the CX-1102.
•Accel/Decel Rates: Adjust the Accel/Decel rates in the motor drive (amplifier), on each axis, to their
fastest rates (shortest time), to allow the CX-1102 command signals to promptly generate a correct
response from the motor. However, adjust the Accel/Decel rates in the CX-1102 to more gentle ramps
to allow the dancer trim to work smoothly and effectively at startup.
•Safety Stops/Inhibits/Enables: The CX-1102 has Drive Enable open collector outputs, to be used (via
pilot relays if needed) to enable/disable the motor drive. This is important since there are situations
where the CX-1102 is trying to hold an axle in a “live zero”, or “active stopped”, H-Stop state. At
other times the axis is turned off (disabled). While the drive enable function could be part of some
external process control scheme, it is best to let the CX-1102 control the drives as required by the
internal control algorithms. Having said this, also consider SAFETY. The CX-1102 stop commands
are solid state items. Overall system safety would require interlocked, external, pushbuttons, contacts,
etc. to effect a disconnect type of safety stop. CX-1102’s “live zero” may appear to be a stopped
condition, but would NOT be safe to enter the machine for thread-up, jam clearing, etc.
•Web Stretch: Greatest accuracy is obtained with
Non-extensible webs. Some minor (<2%) web
stretch, or shrinkage, is usually acceptable but may affect line speed accuracy. If web stretch is
expected, enter the anticipated stretch value into Stretch % (CP-220) to normalize the dancer trim
effect.
•Unipolar (Non-reversible) Drives: The CX-1102 is typically used with bi-directional (reversible)
drives. It can accommodate unipolar drives (or brake in limited cases), only with appropriate design
considerations. The unipolar drive axis must have sufficient gearbox friction to prevent back-driving,
or overhauling loads. That is, it must prevent being pulled backwards, or pulled forwards faster than it
intended to go, due to web tension. Otherwise, the dancer position cannot be maintained properly.
Page 2
—NOTES—
Page 3
BASIC WIRING
WARNING
The CX-1102 should only be installed by a qualified electrician.
Hazardous voltages may cause severe injury, death or equipment
damage.
The CX-1102 General Wiring Diagram illustrates the complete power and signal wiring for the CX-1102 control. Not
all of the connections will be required for your application. Refer to the CX-1102 Technical Reference Manual for
complete installation and wiring instructions.
The following instructions describe the basic wiring required for the unwind and wind modes of operation:
Power (J4 pins 1,2,3)
Position the power selector switch on the back of the CX-1102 to configure the power supply for 115 or 230 VAC. Wire
the power as shown in the diagram for 115 or 230 VAC.
WARNING
Applying 230 VAC power with the power selector switch in the
115 position will result in damage to the CX-1102 controller.
Run/Stop Logic (J6 pins 1,2,3,4,6)
In order to put the CX-1102 into “Run”, the F-Stop, Unload and H-Stop inputs must be shorted to common, usually
through a normally closed pushbutton. Short the Run input to common, usually through a normally open momentary
pushbutton. Thereafter, opening any of the Stop inputs will cause the CX-1102 to stop.
Unwind Jog Fwd/Rvs (J7 pins 1,2,3)
Unwind Jog Fwd/Rvs is a maintained input. When it is closed, it sends a Control Output signal to the drive at the
selected Jog Setpoint. As a maintained input, Unwind Jog Fwd/Rvs is only active when the operator device is closed.
Wind Jog Fwd/Rvs (J7 pins 4,5,3)
Wind Jog Fwd/Rvs is a maintained input. When it is closed, it sends a Control Output signal to the drive at the selected
Jog Setpoint. As a maintained input, Wind Jog Fwd/Rvs is only active when the operator device is closed.
Unwind Control Output (J3 pins 1,2)
The Unwind Control Output is a two wire connection between the CX-1102 and the Unwind motor drive. Insure that the
isolated common (J3 pin 2) is not used elsewhere.
Wind Control Output (J8 pins 1,2)
The Wind Control Output is a two wire connection between the CX-1102 and the Wind motor drive. Insure that the
isolated common (J8 pin 2) is not used elsewhere.
Unwind Enable and Wind Enable (J2 pins 1,2,3,10)
When these digital outputs are wired to the appropriate control input of the subject drive, it allows the CX-1102 to enable
and disable the drive as required. A low voltage pilot relay is usually required.
Frequency Inputs (J5 pins 1 thru 11)
The CX-1102 requires quadrature encoders for the unwind/wind frequency inputs. Refer to the CX-1102 TechnicalReference Manual for detailed diagrams illustrating the connections for the frequency sensors.
Setup (J6 pin 10,8)
The Setup input is a maintained input. It is used only during the system setup procedure to put the CX-1102 into “Setup
State”.
KeyLk (J6 pin 9,8)
The KeyLk input is a momentary input. It is used temporarily during the system setup procedure of the CX-1102.
Page 4
CX-1102 General Wiring Diagram
RS485
Serial
Communications
Interface
+
EXTERNAL
DC
POWER
SUPPLY
(50V MAX)
-
Signal Input
Drive Common
Unwind Motor Drive
Signal Input
Drive Common
Wind Motor Drive
TD/RD +
TD/RD -
Com
Unwind Enable
Wind Enable
Unwind Error
Wind Error
Wind Roll Full
Dancer
Web Break
Spare
FUSES
1 A
250 V
230 VAC
115 VAC
L1
L1
L2
NEUT
GND/PE
GND/PE
Dancer
Line Speed
JA
+5VDC
1
Dncr
2
LnSpd
3
Com
4
Analog Card
J3
SigU
1
ComU
2
Output
Control
To UWnd Drv
J8
SigW
1
ComW
2
Output
Control
To Wnd Drv
J1
TD/RD +
1
TD/RD -
2
Com
3
RS485
Serial Comm
J2
+V_DO
1
R
R
R
R
R
R
R
R
UwdEn
2
WdEn
3
UErr
4
WErr
5
WRlFl
6
Dncr
7
WbBrk
8
Spare
9
Com
10
Digital Outputs
J4
L1
1
L2/NEUT
2
GND/PE
3
INPUT
AC POWER
J5
* +5VDC
UnWindWind
A
-
A
B
Encode Inputs
-
B
Com
A
-
A
B
-
B
Reserved
Com
RI_1
RI_2
J6
F-Stp
UnLd
Com
H-Stp
Load
Run
Spare
Com
KeyLk
Digital Inputs
Setup
J7
UJogF
UJogR
Com
WJogF
WJogR
UuWrp
WuWrp
Com
LSRvs
WbRst
1
2
3
4
5
6
7
8
9
10
11
NC
12
NC
13
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
+5V PWR
A
-
A
B
-
B
Common
A
-
A
B
-
B
Common
+5V PWR
Unwind
Quadrature
Sensor
Wind
Quadrature
Sensor
F-Stop
UnLoad
H-Stop
Load
Run
Spare
Keypad Lockout
Setup
Unwind Jog Forward
Unwind Jog Reverse
Wind Jog Forward
Wind Jog Reverse
Unwind Under Wrap
Wind Under Wrap
Line Speed Reverse
Web Reset
CX-1102
*
Power for frequency input sensors may be supplied by J5, pin 1.
Total current should not exceed 150 mA .
Page 5
OPERATOR INTERFACE PRIMER
The remainder of the CX-1102 setup procedure involves setting control parameter values through the operator interface,
and then verifying system behavior using monitor parameters. The basic procedure for changing a control parameter is
first to locate the relevant parameter using the Menu, Page Up/Down and Parameter Up/Down keys, and then to modify
the parameter value using the Numeric or Scroll Up/Down keys.
The sequence for locating a control or monitor parameter using the menu driven interface is:
•Press the Menu key repeatedly until the Main Menu is displayed.
•Press the Parameter Up/Down keys to select the sub menu.
•Press the Enter key.
•Press the Parameter Up/Down keys to select the parameter category.
•Press the Enter key.
•Press the Page Up/Down keys, if necessary, to select the page.
•Press the Parameter Up/Down keys to select the parameter.
An alternative method for locating a parameter is through the code select procedure:
•Press the Code key to activate the code select line.
•Enter the numeric parameter code.
•Press the Enter key.
•The selected parameter is now displayed on the Status screen.
For each control parameter (CP) and monitor parameter (MP) required, the menu path will be shown as:
Go to MAIN MENU\DEVICE SETUP\SYSTEM SETUP\PAGE 1.
Enter App Select {CP-202} = 0 = Direct Mode.
The menu selections are separated by back slashes, “\”. The parameter code is
shown in the brackets,{}.
NOTE:The Help key accesses the Help screen and gives you a brief description of the parameter or subject that is
highlighted (active) on the screen. Press the Help key again to return to the previous screen.
Page 6
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