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
CT34002a_e.doc / Nov-15 Page 1 / 42
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 2 / 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
CT34002a_e.doc / Nov-15 Page 3 / 42
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)
Figure: SM300 mounting bracket for DIN rail mounting of CT340 units
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.
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.
CT34002a_e.doc / Nov-15 Page 4 / 42
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.
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.
CT34002a_e.doc / Nov-15 Page 5 / 42
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
3. Electrical Connections
CT34002a_e.doc / Nov-15 Page 6 / 42
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
CT34002a_e.doc / Nov-15 Page 7 / 42
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).
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”
CT34002a_e.doc / Nov-15 Page 8 / 42
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
2
3
5
RxD
TxD
GND
screen
PC
CT 340
14
(Sub-D-9)
30
31
TxD
RxD
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.
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
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.
CT34002a_e.doc / Nov-15 Page 9 / 42
Cut
V
Line
Sync Zone
t
Cut
V
Line
Sync Zone
t
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:
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.
CT34002a_e.doc / Nov-15 Page 10 / 42
Please observe the minimum duration of 50 µs for the cutting pulse!
4.2. System Configuration
As a master drive, either the motor of a feed roll or a measuring wheel equipped with an
incremental encoder is used.
The encoder resolutions should be at least 5 times higher than the maximum acceptable
cutting error.
At maximum line speed, the master encoder frequency should be at least about 1 kHz, for best
resolution of the analogue output. Moreover, the input frequency must not exceed the
maximum level of 300 kHz (RS422 and TTL differential encoder) or 200 KHz (HTL and TTL singleended encoders).
It is best to choose the ppr numbers of line and cutting roll encoders in a way to produce
frequencies in the same range. Acceptable ratios are in the range of
5:1 ... 1:1 ...1:5
Mismatching beyond 1:16 and 16:1 are not allowed. Where applicable, the (x1), (x2) or (x4)
hardware multiplication of the Master channel or the Slave channel may be used to adapt the
frequencies
The line encoder must be connected to input 1 (Master) and the cutting roll encoder to
input 2 (Slave).
For speed reference of the cutting roll drive the analogue output is used.
The unit must receive a “cutting pulse” with each revolution of the cutting roll. You can use an
external sensor (proximity switch, light barrier) or the zero pulse of the cutting roll encoder, if it
is an HTL encoder and if the encoder is fitted directly to the cutting roll with no gear ratio
between.
It is necessary to adjust the cutting roll drive to its maximum dynamic response (no internal
ramps, no integral control loop, high proportional gain), because the CT340 and CT641 will
generate the ramps which the drive has to follow with no additional delay
Two inputs “Jog / Trim” provide manual displacement of the cutting point on the material and
also allow jogging the cutting roll with in standstill.
After power-on or after manually moving of the cutting roll, e. g. by Jog function, you can
perform a homing sequence to move the cutting roll to its home position. When you start the
homing sequence, the cutting roll moves with a register settable speed till the cutting pulse
appears. Then it moves on to the home position, which is located opposite to the centre point
of the synchronous zone.
CT34002a_e.doc / Nov-15 Page 11 / 42
PROG
UP
DOWN
ENTER
Setup operation is disabled while the cutting roll is within a cutting cycle.
I. e. the setup procedure cannot be started before the Start command has been
released and the cutting roll has returned to its home position.
P
5. Keypad Operation
An overview of all parameters and explanations can be found under section 7.
The menu of the unit uses four keys, hereinafter named as follows:
Key functions depend on the actual operating state of the unit. Essentially we have to describe
three basic states:
Normal operation
General setup procedure
Direct fast access to scaling factors
5.1. Normal Operation
In this mode the unit operates to the settings defined upon setup. All front keys may have
customer-defined functions according to the specifications met in the keypad definition menu
F06 (e.g. Display scroll, Immediate Cut or else)
5.2. General Setup Procedure
The unit changes over from normal operation to setup level when keeping the key down
for at least 2 seconds. Thereafter you can select one of the parameter groups F01 to F09.
Inside the group you can now select the desired parameter and set the value according to need.
After this you can either set more parameters or return to the normal operation.
The adjoining sequence of key operations explains how to change
Parameter number 052 of group F06 from the original value of 0 to a new value of 8
CT34002a_e.doc / Nov-15 Page 12 / 42
Step
State
Key action
Display
Comment
00
Normal operation
Actual Error
01
> 2 sec.
F01
Display of the
Parameter group
02
Level:
Parameter group
5 x F02 … F06
Select group # F06
03
F06.050
Confirmation of F06.
The first parameter of this
group is F06.050
04
Level:
Parameter numbers
2 x
F06.051…
F06.052
Select parameter 052
05
0
Parameter 052 appears in
display, actual setting is 0
06
Level:
Parameter values
8 x 1 …. 8
Setting has been modified
from 0 to 8
07
F06.052
Save the new setting (8)
08
Level:
Parameter numbers
F06
Return to level parameter
groups
09
Level:
Parameter groups
Actual Error
Return to normal operation
10
Normal operation
During the general setup procedure all control activities remain disabled. New
parameter settings become active after return to normal operation only.
and
at the same time
Direct fast access is enabled when the cutting roll is within a cutting cycle.
During the fast access procedure all control functions remain fully active.
Access is limited to cutting length setting; no other parameters can be changed.
5.3. Direct Fast Access to Cutting Length Setting
To get to the fast access routine, please press both
This will access the parameter group F01 right away. To change the cutting length setting
follow the same procedure as already described above.
Besides the advantage of direct access, the fundamental difference to general setup is the
following:
CT34002a_e.doc / Nov-15 Page 13 / 42
PROG
UP
DOWN
ENTER
Saves the actual value
shown in the display and
returns to the parameter
selection level
Increments the
highlighted
(blinking) digit
Decrements the
highlighted
(blinking) digit
Shifts the cursor (blinking
digit) one position to the
left, or from utmost left
to right
Step
Display
Key action
Comment
00
001024
Display of actual parameter setting, last
digit is highlighted
01
4 x
Scroll last digit down to 0
02
001020
Shift cursor to left
03
001020
2 x
Scroll highlighted digit down to 0
04
001000
2 x
Shift curser 2 positions left
05
001000
Scroll highlighted digit down to 0
06
000000
Shift cursor left
07
000000
5 x
Scroll highlighted digit up to 5
08
050000
Shift cursor left
09
050000
2 x
Scroll highlighted digit up to 2
10
250000
Save new setting and return to the
parameter number level
P
5.4. Change of Parameter Values on the Numeric Level
The numeric range of the parameters is up to 6 digits. Some of the parameters may also include
a sign. For fast and easy setting or these values the menu uses an algorithm as shown
subsequently. During this operation the front keys have the following functions:
With signed parameters the left digit scrolls from 0 to 9 and then shows “–„ (negative) and
“-1“ (minus one). The example below shows how to change a parameter from the actual setting
of 1024 to the new setting of 250 000.
This example assumes that you have already selected the parameter group and the parameter
number, and that you actually read the parameter value in the display.
Highlighted digits appear on colored background.
CT34002a_e.doc / Nov-15 Page 14 / 42
Switch power off
Press
and
simultaneously
Switch power on while you keep down both keys
Where you decide to take this action, please note that all parameters and
settings will be lost, and that you will need to run a new setup procedure again.
5.5. Code Protection against Unauthorized Keypad Access
Parameter group F09 allows to define an own locking code for each of the parameter menus.
This permits to limit access to certain parameter groups to specific persons only.
When accessing a protected parameter group, the display will first show “CODE” and wait for
your entry. To continue keypad operations you must now enter the code which you have stored
before, otherwise the unit will return to normal operation again.
After entering your code, press the ENTER key and keep it down until the unit responds.
When your code was correct, the response will be “YES” and the menu will work normally.
With incorrect code the response will be “NO” and the menu remains locked.
5.6. Return from the Programming Levels and Time-Out Function
At any time the PROG key sets the menu one level up and finally returns to normal operation.
The same step occurs automatically via the time-out function, when during a period of 10
seconds no key has been touched.
Termination of the menu by automatic time-out will not store new settings, unless they have
already been stored by the PROG key after editing.
5.7. Reset all Parameters to Factory Default Values
Upon special need it may be desirable to set all parameters back to their original factory
settings (e.g. because you have forgotten your access code, or by too many change of settings
you have achieved a complex parameter state). Default values are indicated in the parameter
tables shown later.
To reset the unit to default, please take the following steps:
CT34002a_e.doc / Nov-15 Page 15 / 42
Group
Function
Group
Function
F01
Length Setting
F03
Definitions for the Master Encoder
000
Cutting Length
026
Encoder Properties
001
Reserved
027
Edge Counting
F02
Operational Setting
028
Counting Direction
002
Circ. Master
029
Speed Display Factor
003
PPR Master
030
Speed Display Divider
004
Circ. Cutter
031
Speed Display Dec.Point
005
PPR Cutter
F04
Definitions for the Slave Encoder
006
Trim Time
032
Encoder Properties
007
Correction Divider
033
Edge Counting
008
Ramp Form
034
Counting Direction
009
Sync. Before Cut
035
Reserved
01
Sync. After Cut
036
Reserved
011
Sampling Time
037
Reserved
012
Wait Time
F05
Analogue Output Settings
013
Max. Master Frequency
038
Analogue Format
014
Cuts per Revolution
039
Offset Correction
015
Vmax/Vline
040
Gain Correction
016
Home Window
041
Max. Correction
017
Jog Speed
042
Offset Total
018
Jog / Home Ramp
043
Gain Total
019
Home Speed High
044
Reserved
020
Home Speed Low
045
Reserved
021
Home Switchpoint
022
+/- Sync. Rate (%)
023
Alarm Level
024
Cutting Pulse Offset
025
Reserved
6. Menu Structure and Description of Parameters
All parameters are arranged in a reasonable order of functional groups (F01 to F09)
You must only set those parameters which are really relevant for your specific application.
Unused parameters can remain as they actually are.
6.1. Summary of the Menu
This section shows a summary of the parameter groups, with an assignment to the functional
parts of the unit.
CT34002a_e.doc / Nov-15 Page 16 / 42
F06
Command Assignment
F09
Keypad protection codes
046
Key Up Function
072
Protect Group F01
047
Key Down Function
073
Protect Group F02
048
Key Enter Function
074
Protect Group F03
049
Input 1 Configuration
075
Protect Group F04
050
Input 1 Function
076
Protect Group F05
051
Input 2 Configuration
077
Protect Group F06
052
Input 2 Function
078
Protect Group F07
053
Input 3 Configuration
079
Protect Group F08
054
Input 3 Function
080
Protect Group F09
055
Input 4 Configuration
081
Reserved
056
Input 4 Function
082
Reserved
057
Reserved
083
Reserved
F07
Serial communication
084
Reserved
058
Unit Number
085
Reserved
059
Serial Baud Rate
086
Reserved
060
Serial Format
087
Reserved
061
Reserved
062
Reserved
063
Reserved
F08
Special functions
064
Input Filter
065
Trigger Threshold 1
066
Trigger Threshold 2
067
Brightness
068
Frequency Control
069
Length Store Configuration
070
Display Time
071
Default Display
Master
Slave
Cont1
Cont2
Cont3
Cont4
Digital
Control
Inputs
RS232
K1 out
K2 out
K3 out
K4 out
Alert
Outputs
+/-10V
20 mA
Analogue
Outputs
P ENT
F10
F04
F06 F09
F06
F06
F05
F07
up
dn
F08
F01
F03 F01
The following schematics shows how in principle the parameter blocks are assigned to the
various elements and functions of the controller.
CT34002a_e.doc / Nov-15 Page 17 / 42
F01 Range
Default
F01.000
Cutting Length:
Preset of the desired cutting length scaled in length units.
1 … 999999
10000
F02 Range
Default
F02.002
Circ. Master:
This register must be set to the circumference of the line
feed roll or the measuring wheel of the line encoder.
Setting in length units you decided to use.
1 … 99999
1000
F02.003
PPR Master:
Pulses per revolution of the line encoder.
Enter the number of pulses from the encoder for one
revolution of the feeding roll or measuring wheel with
regard to the multiple edge count setting (x1, x2, x4).
1 … 999999
1000
F02.004
Circ. Cutter:
Circumference of the cutting roll scaled in length units.
1 … 99999
1000
F02.005
PPR Cutter:
Pulses per revolution of the cutting roll.
Enter the number of pulses from the encoder for one
revolution of the cutting roll with regard to the multiple
edge count setting (x1, x2, x4).
1 … 999999
1000
F02.006
Trim Time:
Adjustment time for one increment of cut position
displacement with use of the Trim function.
To be entered as number of cycles (1 cycle = 250 µsec)
per increment.
001 = Displacement of one increment each 250 µs
(fast)
999 = Displacement of one increment each 0.25 s
(slow)
1 … 999
100
6.2. Description of the Parameters
Prior to register setting you must decide which dimensions or length units (LU) you like to use
for preset of the cutting length. This could be 0.1mm or 1mm or 0.001 inch or any other
resolution you desire. All further settings refer to the Length Units you decided to use. E.g.
when you chose to set the length with a 0.1 mm resolution, 1000 LUs will represent a length of
100.0 millimeters with all further entries.
6.2.1. Length Setting
6.2.2. Operational Settings
CT34002a_e.doc / Nov-15 Page 18 / 42
F02 Range
Default
F02.007
Correction Divider:
Function to provide a digital attenuation of the phase
correction signal that is produced, when the drive on
mechanical grounds (dead band or backlash) cannot respond.
In such a case, it is not desirable to make corrections
immediately. The "Correction Divider" provides a window for
the drive "backlash", within which the controller produces no
correction and a division of the differential error count.
0 = No window, Reaction to 1 increment, no division
1 = Window +/- 1 increments, error division by 2
2 = Window +/- 2 increments, error division by 4
3 = Window +/- 4 increments, error division by 8
etc.
0 … 9
0
F02.008
Ramp Form:
Selects the shape of the ramps of the cutting roll speed
profile:
0: Parabolic s-ramps
(recommended in general with standard servo drives)
1: Linear ramps
(recommended with less dynamic systems, e.g. DC drives)
2: sin² shaped ramps
(recommended with extremely dynamic servo systems)
0 … 2
0
F02.009
Sync. Before Cut:
This register defines, how long before the cut (edge of the
virtual cutting pulse) the cutting roll must be synchronous to
the line.
Setting scaled in length units.
1 … 9999
10
F02.010
Sync. After Cut:
This register defines, how long after the cut (edge of the
virtual cutting pulse) the cutting roll must remain
synchronous before the speed profile starts to change speed.
Setting scaled in length units.
Sync before cut
Line speed
Sync after cut
Cutting roll speed
Cutting pulse
1 … 9999
10
CT34002a_e.doc / Nov-15 Page 19 / 42
F02 Range
Default
F02.011
Sampling Time:
Sets the internal digital feed forward control with
respect to dynamics and resolution.
Lower set values result in faster response, but less
accuracy of the feed forward signal. Higher set values
result in better accuracy, but slower response with
sudden speed changes.
Feed forward signals with lower accuracy do not at all
affect speed accuracy of the synchronizing process, but
only might cause slight angular errors.
Depending of the maximum Master encoder frequency,
the subsequent setting can be recommended:
0.001 … 9.980
(seconds)
0.001
fmax
Sampling -Time
1 kHz
0.100 s
3 kHz
0.033 s
10 kHz
0.010 s
30 kHz
0.003 s
≥ 100 kHz
0.001 s
F02.012
Wait Time:
Not applicable, leave at default setting.
0.01 … 9.99
9.99
F02.013
Max. Master Frequency:
Sets the expected maximum input frequency on the
Master encoder input, i. e. the line encoder frequency at
maximum line speed. You should add a 10% reserve to
the real maximum frequency. The unit will not process
frequencies higher than this setting.
0.1 …300000.0
(Hz)
30000.0
F02.014
Cuts per Revolution:
Number of cuts per revolution of the cutting roll.
Set this register to 1 when your cutting roll has only one
tool at its circumference to perform one single cut per
revolution.
When you have mounted two or more tools around the
cutting roll, there are two different ways of setting this
register to perform two or more cuts by every revolution
of the cutting roll:
1…99
1
CT34002a_e.doc / Nov-15 Page 20 / 42
a. If you have more than one tool but only one single cutting pulse per revolution of the cutting
roll, then set register “Cuts per Rev.” to the number of cuts performed by one revolution of the
cutting roll. The controller will generate the missing cutting pulses internally.
Example:
Two cuts per revolution but only one cutting pulse
→ “Set Cuts per Revolution“ = 2
b. If you perform several cuts per revolution of the cutting roll and each cut generates its own
separate cutting pulse, then proceed as follows:
Set register “Cuts per Revolution” to 1.
Do not set register “Circ. Cutter” to the real circumference of the cutting roll but set it to
the partial circumference between two tools.
Also set register “PPR Cutter” to the number of pulses between two tools at the cutting
roll.
Example:
Two cuts per revolution and also two cutting pulses
→ Set “Cuts per Revolution“ = 1,
“Circ. Cutter” = ½ cutting roll circumference and
“PPR Cutter” = ½ number of pulses per revolution.
F02 Range
Default
F02.015
Vmax / V line:
This setting is important only when the range of cutting lengths
includes lengths shorter than the roll circumference, so the roll
must accelerate between two cuts. The register sets the maximum
speed ratio between the circumferential roll speed and the line
speed that the drive will take when required.
This means, whenever you cut shorter length, it is necessary the
slave drive can at least run double line speed. The higher the ratio,
the shorter the minimum length you can cut. It is important to know
that this ratio setting does not refer to the maximum line speed, but
to the real line speed you use when cutting short length. You are
free to reduce your line speed with shorter length preset and i. e.
set this register to 8. But then you must be sure that the cutter drive
can really run 8 times the line speed you actually use for your
shortest length. In general, setting 8 is recommended.
2…8
8
F02.016
Home Window:
Sets a window scaled in length units around the home position of
the cutting roll, which is located opposite to the centre point of the
synchronous zone.
The output “Home” indicates that the cutting roll position is inside
this window.
1 …
999
100
CT34002a_e.doc / Nov-15 Page 21 / 42
F02 Range
Default
F02.017
Jog Speed:
Speed setpoint in Volt for Jog operations by use of input
“Jog forward” or “Jog reverse”.
0.01 … 10.00
1.00
F02.018
Jog / Homing Ramp:
Ramp time in seconds for Jog operations and homing
sequence with respect to speed changes between
standstill and maximum speed (setpoint 10 V)
0 … 99
1
F02.019
Home Speed High:
Fast Homing speed setpoint in Volts. Every homing cycle
will start with this speed.
0.01 … 10.00
2.00
F02.020
Home Speed Low:
Slow Homing speed setpoint in Volt. A Homing cycle
will end with this speed.
0.01 … 10.00
0.50
F02.021
Home Switchpoint:
Distance from the final home position where the speed
changes over from high speed to low speed within a
homing cycle.
Setting scaled in length units.
1 … 99999
100
F02.022
+/- Sync. Rate (%):
This register allows a percental adaption of the
synchronous speed in a range of +/- 99.99%. In general,
this register will be set to 0 and the cutting roll will
synchronize with the line exactly according to the
encoder information.
Some applications may require slightly higher or lower
speed during the synchronous zone, e. g. due to the
cutting tool design.
This setting affects the synchronous speed only, but not
the cutting length!
-99.99
…+99.99
0
F02.023
Alarm Level:
Defines the switching threshold of the output “Alert”
when the system is forced out of synchronization due to
external events (drive fault or mechanical problem).
Setting occurs in cutting roll encoder increments and
the Alert output switches on when the positional error
of the roll in respect to the scheduled position
overpasses the number of encoder pulses set.
0 … 9999
100
CT34002a_e.doc / Nov-15 Page 22 / 42
F02 Range
Default
F02.024
Cutting Pulse Offset:
Offset register for virtual displacement of the physical
cutting pulse (generated from encoder index or by
proximity). Setting in +/- encoder increments. This
register makes superfluous a precise mechanical
adjustment of the location of the pulse (the virtual
cutting pulse must be located exactly in the peak
position of tool penetration).
-999999 …
+999999
0
F03 Range
Default
F03.026
Encoder properties
0 … 3
1
0=
Differential Impulses A, /A, B, /B (2 x 90°) incl. inv.
1=
Single-ended Impulses A, B (2 x 90°) without inv.
F03.027
Edge counting
0 … 2
0
0=
Simple edge evaluation (x1)
1=
Double edge evaluation (x2)
2=
Full quadrature edge evaluation (x4)
F03.028
Counting direction
0 … 1
0
0=
Up when A leads B
1=
Down when A leads B
F03.029
Speed Display Factor
Multiplication factor to calculate the speed display value
from the master frequency (see chapter 7.3)
1 … 999999
1
F03.030
Speed Display Divider
Divider to calculate the speed display value from the master
frequency (see chapter 7.3)
1 … 999999
1
F03.031
Speed Display Dec.Point
Position of decimal point for the speed display value (see
chapter 7.3)
0 … 5
0
6.2.3. Definitions for the Master Encoder
CT34002a_e.doc / Nov-15 Page 23 / 42
F04 Range
Default
F04.032
Encoder properties
0 … 3
1
0=
Impulses A, /A, B, /B (2 x 90°) incl. inv.
1=
Impulses A, B (2 x 90°) without inv.
F04.033
Edge counting
0 … 2
0
0=
Simple (x1)
1=
Double (x2)
2=
Full quadrature (x4)
F04.034
Counting direction
0 … 1
0
0=
Up when A leads B
1=
Down when A leads B
F04.035
n.a.
F05 Range
Default
F05.038
Control characteristics and analogue format
0 … 3
0
0=
Output scaled for a -10 volts … +10 volts signal
1=
Output scaled for a -10 volts … +10 volts signal
2=
Output scaled for a -20 mA … +20 mA signal
3=
Output scaled for a -20 mA … +20 mA signal
F05.039
Offset Correction:
Digital setting of analogue offset on correction signal.
-10.000 … +10.000
(volts)
0.000
F05.040
Gain Correction:
Digital setting of the proportional gain of the control
loop. Setting to 2.048 results in a response of 1 mV
per error bit. Recommended setting: 0.500...5.000
(Gain Correction / 2048 = x.xxx volts per error bit).
0 … 51.200
2.000
F05.041
Max. Correction:
Limitation of the output voltage of the correction
signal (correction will not exceed this setting)
0 … 10.000
(volts)
2.000
F05.042
Offset Total:
Digital setting of analogue offset of the overall
analogue output signal.
-10.000 … +10.000
(volts)
0.000
F05.043
Gain Total:
Sets the full-scale output voltage at maximum master
frequency (see parameter F02.013 Max. Master
Frequency), i.e. 9,000 means 9 volts at max. frequency
0 … 99.999*
(volts)
10.000
6.2.4. Definitions for the Slave Encoder
n.a. = not applicable
6.2.5. Analogue output definitions
*) The real analogue output voltage is physically limited to 10 V
CT34002a_e.doc / Nov-15 Page 24 / 42
F06 Range
Default
F06.046
Function assignment to key „UP“
0 … 16
0
0=
No function
1=
Reset
2=
Start
3=
Immediate Cut
4=
Homing
For more details about these
functions see section 7.1
5=
n.a.
6=
n.a.
7=
Store to EEPROM
8=
Scroll Display
9=
n.a.
10=
Jog / Trim forward
11=
Jog / Trim backward
12=
Clear Batch Counter
13=
n.a.
14=
Read front thumbwheels (model CT 641 only)
15=
Clear Error
16=
n.a.
F06.047
Function assignment to key „DOWN“
0 … 16
0
See key „UP“
F06.048
Function assignment to key „ENTER“
0 … 16
0
See key „UP“
6.2.6. Key command assignments
n.a. = not applicable
CT34002a_e.doc / Nov-15 Page 25 / 42
F06 Range
Default
F06.049
Switching characteristics of input „Cont.1“
0 … 7
0
0=
NPN (switch to -), function active LOW
1=
NPN (switch to -), function active HIGH
2=
NPN (switch to -), rising edge
3=
NPN (switch to -), falling edge
4=
PNP (switch to +), function active LOW
5=
PNP (switch to +), function active HIGH
6=
PNP (switch to +), rising edge
7=
PNP (switch to +), falling edge
F06.050
Function assignment to input „Cont.1“
0 … 16
6
0=
No function
1=
Reset
2=
Start
3=
Immediate Cut
4=
Homing
For more details about these
functions see section 7.1
5=
n.a.
6=
Cutting Pulse
7=
Store to EEPROM
8=
Scroll Display
9=
Parameter Input Disable
10=
Jog / Trim forward
11=
Jog / Trim backward
12=
Clear Batch Counter
13=
n.a.
14=
Read front thumbwheels (model CT 641 only)
15=
Clear Error
16=
n.a.
F06.051
Switching characteristics of input „Cont.2“
See „Cont.1“ (F06.049)
F06.052
Function assignment to input „Cont.2“
See „Cont.1“ (F06.050)
F06.053
Switching characteristics of input „Cont.3“
See „Cont.1“ (F06.049)
F06.054
Function assignment to input „Cont.3“
See „Cont.1“ (F06.050)
F06.055
Switching characteristics of input „Cont.4“
0 – 3
0=
NPN (switch to -) function active LOW
no edge-triggered functions are
possible with Cont.4
1=
NPN (switch to -) function active HIGH
2=
PNP (switch to +), function active LOW
3=
PNP (switch to +), function active HIGH
F06.056
Function assignment to input „Cont.4“
See „Cont.1“ (F06.050)
6.2.7. Characteristics and functions of the Control Inputs
n.a. = not applicable
CT34002a_e.doc / Nov-15 Page 26 / 42
Unconnected NPN inputs are always HIGH (internal pull-up resistor)
Unconnected PNP inputs are always LOW (internal pull-down resistor)
It is mandatory to assign the Cutting Pulse to one of the inputs 1, 2 or 3 (F06.050
or F06.052 or F06.054 = 6). The selected input is no more available for other
purpose.
The Cutting Pulse input must always be edge-triggered, i.e. the corresponding
parameters F06.049, F06.051 or F06.053 be either 2 or 3 or 6 or 7
Where you like visualize the Cutting Pulse Signal on your PC screen by means of
the OS32 Operator Software, you must temporary set the inputs to static
operation as the corresponding light boxes on the screen are not suitable to
display dynamic signals. Please do not forget to return to edge-triggered
operation after the test!
F07 Range
Default
F07.058
Serial device address (unit number)
11 … 99
11
F07.059
Serial baud rate
0 … 6
0
0=
9600 Baud
1=
4800 Baud
2=
2400 Baud
3=
1200 Baud
4=
600 Baud
5=
19200 Baud
6=
38400 Baud
F07.060
Serial data format
0 … 9
0
0=
7 Data, Parity even, 1 Stop
1=
7 Data, Parity even, 2 Stop
2=
7 Data, Parity odd, 1 Stop
3=
7 Data, Parity odd, 2 Stop
4=
7 Data, no Parity, 1 Stop
5=
7 Data, no Parity, 2 Stop
6=
8 Data, Parity even, 1 Stop
7=
8 Data, Parity odd, 1 Stop
8=
8 Data, no Parity, 1 Stop
9=
8 Data, no Parity, 2 Stop
6.2.8. Serial communication parameters
CT34002a_e.doc / Nov-15 Page 27 / 42
F08 Range
Default
F08.064
Digital input filter: must be set to “0”.
0 … 3
0
F08.065
Trigger threshold for encoder1 inputs *)
30 … 250
166
F08.066
Trigger threshold for encoder2 inputs *)
30 … 250
166
F08.067
Brightness of the 7-segment LED display
0 … 4
0
0=
100% of maximum brightness
1=
80% of maximum brightness
2=
60% of maximum brightness
3=
40% of maximum brightness
4=
20% of maximum brightness
F08.068
Frequency Control: must be set to “0”
0 … 1
0
F08.069
Length Storage
0 … 1
0
0=
Cutting length set by the “Direct Fast Access”
menu (see chapter 5.3) is only temporary active
until next power-down.
1=
Cutting length set by the “Direct Fast Access”
menu (see chapter 5.3) is stored to EEPROM for
enduring use.
F08.070
Display Time: Update time (sec.) for display only
0.005 … 9.999
0.050
F08.071
Default Display: Number of actual value displayed by
the unit after power up (see table in chapter 7.1 at
description of Scroll Display command)
0 … 8
0
F09 Range
Default
F09.072
Protected group F01
F09.073
Protected group F02
0
F09.074
Protected group F03
0 = no protection
F09.075
Protected group F04
F09.076
Protected group F05
1 – 999 999 =
F09.077
Protected group F06
Protection code
F09.078
Protected group F07
for the actual
F09.079
Protected group F08
parameter group
F09.080
Protected group F09
6.2.9. Special functions
*) Must be set to the default value (166) for any kind of input signals, except for single-
ended TTL signals which require a setting of 35.
6.2.10. Keypad protection codes
CT34002a_e.doc / Nov-15 Page 28 / 42
No.
Command
Description
Assignment to
Keypad
Input
1
Reset
Sets the internal differential counter and the analogue
correction signal to zero. The cutting roll drive runs
solely in analogue synchronization (open loop control)
whilst activated
yes
yes
2
Start
Start of the automatic cutting procedure.
The unit cuts automatically to preset cutting length.
When this command is not set, the cutting roll is held in
its home position (closed loop position control). The
cutting roll can be moved into forward and reverse
direction by use of the inputs “Jog forw” and “Jog rev”.
yes
yes
3
Immediate
Cut
This command will immediately start the cutting roll for
a cutting cycle, independent on what the actual length
is. The subsequent cut will correspond to the preset
length again, unless another Flying Cut will be triggered
again. This function e.g. allows the operator to cut out
bad parts of the material. An immediate cut can also be
performed when the material is in standstill or when
Start command is reset.
yes
yes
4
Homing
Starts a homing cycle and moves the knife to a defined
home position. Within a homing cycle the cutting roll
moves forward till the cutting pulse appears. Then it
moves on to the home position.
Before starting the automatic cutting operation, we
recommend performing a homing cycle if the cutting roll
is not yet in its home position.
yes
yes
5
n.a. no
no
6
Cutting
Pulse
Sensor input for the cutting pulse. For definition of the
knife position, the controller needs one index pulse with
every cut, which can be generated either by a remote
sensor or from the marker pulse of an HTL encoder.
no
yes
7. Description of Commands and Outputs
7.1. Commands
CT34002a_e.doc / Nov-15 Page 29 / 42
No.
Command
Description
Assignment to
Keypad
Input
7
Store to
EEPROM
Stores actual operational settings to the EEPROM, so
they remain available also after power down.
yes
yes
8
Scroll Display
Selects the source of the digital display.
See chapter 7.3 Display for details.
yes
yes
9
Parameter
Disable
Disables the keypad for any parameter access. Only
commands assigned to the keypads will be accessible
no
yes
10
Jog / Trim
Forward
When command “Start” is released:
In stop state the inputs Jog / Trim forward and Jog /
Trim reverse move the cutting roll in one or the other
direction (Jog speed register settable).
After termination of a Jog command, the cutting roll
will be held again in its new position in closed-loop
control.
When command “Start” is set:
At automatic cutting cycles the inputs Jog / Trim
forward and Jog / Trim reverse shift the cutting
position forward or reverse (Trim speed register
settable), i. e. the unit temporarily cuts longer or
shorter pieces while one of the Trim inputs is set.
yes
yes
11
Jog / Trim
Backward
yes
yes
12
Clear Batch
Counter
Resets the internal batch counter to zero.
yes
yes
13
n.a. no
no
14
Read
Thumbwheels
Reads and activates the cutting length setting from the
front thumbwheel switches (model CT641 only)
yes
yes
15
Clear Error
Resets error states and clears the corresponding error
messages (see also chapter 7.4 Error Messages)
yes
yes
16
n.a. no
no
n.a. = not applicable
CT34002a_e.doc / Nov-15 Page 30 / 42
No.
Output
Terminal
K1
Error:
This output goes high when an error is detected during operation
(see section 7.4 “Error Messages”).
X2 / 26
K2
Alert:
Indicates that the cutting roll, with respect to its profile position
set point, actually runs with a positive or negative position error
higher than the limit set at parameter „Alarm Level“.
X2 / 25
K3
Automatic Operation:
Set to on during automatic cutting operation while command
“Start” is set. When the “Start” command is released, this output
is set to off not before the actual cut is finished and the cutting
roll has come to standstill at its home position.
X1 / 10
K4
Homing Done:
Set to on when the homing cycle is finished. Reset to off when
the home position is no more valid and a new homing cycle
should be executed (after Jog, parameter set up or power down).
X1 / 9
–
Home*:
Indicates that the cutting roll is in its home position like defined
by register “Home Window”.
–
–
Virt. Cutting Pulse*:
The rising edge of this signal indicates the virtual cutting pulse at
the cutting position of the knife (see parameter “Cutting Pulse
Offset”).
The output is reset to low at the end of the synchronous zone
after the cut (see parameter “Sync. After Cut”).
–
–
Max. Frequency*:
Indicates that the line speed (line encoder frequency) has
exceeded its maximum value as defined by parameter “Max.
Master Frequency”.
–
–
Unit Ready*:
Indicates that the unit is ready to operate after power-up,
initialization and successful self-test.
–
7.2. Outputs
*) Serial readout only (displayed at PC by OS3.2 operator software)
CT34002a_e.doc / Nov-15 Page 31 / 42
Nr.
Display
L1 (red)
L2 (yellow)
0
Display OFF (only two decimal points are lit to indicate
operation state)
OFF
OFF
1
Position error (differential counter)
OFF
OFF
2
Position error (bar graph display, see diagram below)
OFF
OFF
3
Actual Master speed
The speed display can be scaled by the two parameters
F03.029 Speed Display Factor and F03.030 Speed:
030.03
029.03][
F
FHzfrequencyMaster
valueDisplay
If you want to display a decimal point with the speed
value you can select the position of the decimal point by
parameter F03.031 Speed Display Dec.Point.
ON
OFF
4
Master encoder pulse counter
OFF
ON
5
Cutting roll position scaled in encoder increments
ON
ON
6
Cutting pulse distance scaled in encoder increments
Flashing
OFF
7
Actual cutting length scaled in length units
OFF
Flashing
8
Batch counter
Flashing
Flashing
Slave lags Master
Slave leads Master
-4 ... 0 ... +4
+5 ... +8
+9 ... +16
+17 ... +32
+33 ... +64
> +64
Bar graph display with reference to the actual position error
The diagram shows positive errors only (Slave lags Master). Negative errors are mirror-inverted.
7.3. Display of Actual Values
During normal operation it is possible to display an actual value. Two LEDs at the front panel
indicate the actual value displayed. You can scroll the actual value on the display by Scroll
Display command, which can be assigned either to a key or to an input. Parameter F08.071
“Default Display” selects the actual value to be displayed after power up of the unit.
CT34002a_e.doc / Nov-15 Page 32 / 42
Error No.
Error Description
Error 0
The reason for the error has been rectified (e. g. parameter value amended after
Value Range Error) but the error has not yet been cleared by input “Clear Error”.
Error 1
Cut not possible:
The cut is not possible because the preset cutting length is too low.
Error 2
No Cutting Pulse:
The cutting pulse is missing.
This error will be set if no cutting pulse appears within one revolution of the
cutting roll.
Error 3
Power Low:
The power supply voltage is too low.
This error cannot be cleared before the power supply voltage has recovered and
exceeds the minimum power supply voltage level.
Error 4
Val. Range exceed:
Internal overflow error during pre-calculation of the cutting profile.
This error can occur by the following reasons among others:
The ratio between the number of line encoder pulses and the number of
cutting roll encoder pulses has exceeded the permitted range (see section
4.2 “system configuration” for details).
The value of “Home switchpoint” is too high.
The synchronous zone (sum of “Sync. Before Cut” and “Sync. After Cut”) is
greater than the cutting roll circumference
7.4. Error Messages
Upon detection of an error, the cutting roll remains in a closed-loop standstill at home position
after termination of the current cut. Output “Error” switches to high and the unit displays a
flashing error message “Error…” indicating the error number.
To clear an error state either set “Clear Error” command or cycle the power supply of the unit.
Please note that the unit will immediately return to the error state if the cause for the error has
not been eliminated.
CT34002a_e.doc / Nov-15 Page 33 / 42
Edge triggered events (e.g. Cutting Pulse) cannot be displayed in the OS3.x, due
to the slow serial data transmission.
8. Steps for Commissioning
For easy and uncomplicated commissioning of the CT340 / 641 controllers you need a PC with
the actual operator software OS3.x. You can download this software and full instructions, free
of charge, from our homepage www.motrona.com.
Connect your PC to the synchronizer as shown in section 3.6 and start the OS3.x software. The
following screen will appear:
Where instead you find the mask blank with the indication „OFFLINE“ in the top bar, please
click to the „Comms“ menu and check the serial settings of your PC.
Set all parameters in the Edit filed according to your needs, following the hints given in this
manual. The following parameters should initially be set to the values as shown:
CT34002a_e.doc / Nov-15 Page 34 / 42
Number
Register
Initial Setting
F02.007
Correction Divider
0
F05.040
Correction Gain
1.000
F05.041
Max. Correction
10.000
At this time, both drives (line and cutting roll) must be adjusted to proper and
stable operation over the full speed range. Cutting roll drive settings must
provide a maximum of dynamics and response (set ramps to zero, switch off
any integral or differential component of the internal speed control loop, i.e.
operate the drive with proportional speed control only, with the proportional
Gain set as high as possible).
For the set-up procedure the cutting roll must be able to move in both
directions without any mechanical limitations.
After entry of all parameters click to “Transmit All” followed by “Store EEPROM” to store all
parameters to the CT340 or CT641 controller.
8.1. Running the Adjust menu
For adjustments of directions and control gains of the slave drive, you need to open the
“Adjust” menu available under “Tools” in the main menu of the screen. To start the Adjust
menu the first time, the Slave drive should be disabled for reasons of safety.
CT34002a_e.doc / Nov-15 Page 35 / 42
You can reset the differential counter to zero at any time between, by cycling
the “Reset” command.
8.2. Set Directions of Rotation
The direction of rotation must be defined for both, master and slave encoder. Make sure the
Reset is switched on when you do this (the softkey must show “Reset is ON”)
Move the Master encoder into forward direction (manually or by means of a remote speed
signal to the Master drive). Observe the “Counter Master” value shown in the monitor
window on the right. It must count up to positive values. Where you find it counts down or
to negative, please click to button “Master Direction” to change the counting direction.
Move the Slave encoder into forward direction (manually or by enabling the Slave drive
while the Master is moving forward). Observe the “Counter Slave” value. It must again
count up to positive values. Where you find it counts down or to negative, please click to
button “Slave Direction” to change the counting direction.
8.3. Tuning the Analogue Output
Switch Reset to ON by clicking to the corresponding softkey on the screen.
Enable both, Master and Slave drive. Turn the speed signal for the Master to approximate
25% of the maximum speed. The Slave should now move, too. As a next step, switch the
Reset to OFF by clicking to the Reset button (showing actually “Reset On”). This will
activate the closed loop control.
Observe the color bar and the value of the differential counter. There are the following
two possibilities:
a. The bar graph moves to the right and the differential counter shows positive values.
This indicates that the analogue output is too low. Please increase the setting of
“Gain Total” by scrolling up with the arrow key on the right, or by shifting the slider
into a more right position.
b. The bar graph moves to the left and the differential counter shows negative values.
This indicates that the analogue output is too high. Please decrease the setting of
“Gain Total” by scrolling down with the arrow key on the left, or by shifting the
slider into a more left position.
“Gain Total” is set correctly when the bar graph remains in its centre position and the
differential counter swings around zero (e.g. +/-8 counts)
Turn speed signal for the master to approximately 80% of maximum speed. Continue to
observe the color bar and the value of the differential counter and adjust “Gain Total”
again if necessary.
CT34002a_e.doc / Nov-15 Page 36 / 42
Actual value no. 6 displays the distance between the cutting pulses (see chapter
7.3). Thereby you can check the proper operation of the cutting pulse.
8.4. Setting of the Proportional Gain
The register “Gain Correction” determines how strong the controller responds to position and
speed errors of the drive. In principle, this setting therefore should be as high as possible.
However, depending on dynamics and inertia of the whole system, too high gain values will
produce stability problems.
Please try to increase the setting of Correction Gain from 0.500 to 1.000, 1500, 2.000, 2.500,
3.000 etc. However, as soon as you find unsteady operation, noise or oscillation, you must
reduce the setting again correspondingly.
We also recommend to ramp up and down the master while checking the color bar and the
differential counter for stable operation.
Once you have successfully concluded these steps, you can exit the Adjust menu.
Now your machine is ready for operation and you can run initial test cuts without material (see
next chapter).
8.5. Tuning the controller
Start a homing sequence by activating input “Homing”. The cutting roll performs a homing
sequence and moves to the home position, which is located opposite to the centre of the
synchronous zone.
For the very first trials you should use a long length setting (“Cutting Length”) and a slow
line speed.
Start the line drive or move the measuring wheel at the line encoder to simulate the
moving material.
Set “Immediate Cut” command and see how the controller executes a first cutting cycle.
Set the “Start” command. The cutting roll will wait for expiration of the length and then
continuously execute cutting cycles.
By actual value no. 7 you can display and check the actual cutting length (see chapter
7.3).
Observe the position error at the differential counter or the bar graph display. During the
whole cycle the position error should not exceed values like 30 and the bar graph should
remain in the centre area all the time. Increase the line speed step by step and continue
the observations.
When you have achieved settings to keep the bar graph at the centre position at all line speeds
and with all cutting length presets, there is nothing to improve.
CT34002a_e.doc / Nov-15 Page 37 / 42
If, despite of this, your cutting results should not satisfy you in terms of accuracy or
synchronism, there are definitely mechanical problems or other external reasons outside of the
control loop.
The following hints refer to improvements you can make when bar graph display and
differential counter indicate unusual characteristics:
If many segments of the bar graph display are lit at the same time and the differential counter
shows very unstable values:
The encoder resolution (pulses per length unit) could be much higher than the mechanical
clearance of your gear tooth wheels etc.
Reduce edge count setting from (x4) to (x2) or (x1)
Increase the value of “Correction Divider” (see description of register “Correction
Divider” for details)
Reduce “Gain Correction” setting if this eliminates the problem.
Remark: Even though the bar graph display can indicate a very unstable characteristic, your
cutting accuracy and performance may be good. Then just accept this visual flaw.
If the bar graph display and the differential counter value move up and down with the speed
cycle of the cutter:
Try to increase the setting of register “Gain Correction”.
Check for avoidable ramps and delays in your drive
Possibly the cutter drive is not strong and dynamic enough to follow the speed profile
and / or to generate enough torque at the time the tool penetrates the material
Reduce the line speed for all length settings where you observe this problem.
Remark: This must not really affect your cutting performance. When the cutting accuracy is
good, you can accept this visual flaw. Position errors will not affect the cutting accuracy, unless
they occur directly during the cut and differ from cut to cut, because position errors repeating
continuously from cut to cut may eliminate themselves.
This concludes the procedure of commissioning of your rotating cutter system. We recommend
saving all parameter settings on hard disc or disc. In case of repeat applications (machine with
similar specifications), or after exchange of the controller, you just need to download the
settings and are immediately ready to go.
CT34002a_e.doc / Nov-15 Page 38 / 42
2 31 5 64 8 97 11 1210
X3
K4-C
K4-NO
K4-NC
K3-C
K3-NO
K3-NC
K2-C
K2-NO
K2-NC
K1-C
K1-NO
K1-NC
REL.4 REL.3 REL.2 REL.1
C =
NO =
Common contact
NC =
Normally open
Normally closed
9. Appendix for model CT 641
9.1. Relay Outputs
While model CT340 provides high-speed transistor outputs only, model CT641 provides four
additional relay outputs, operating in parallel to the high-speed transistor outputs K1 – K4.
All electrical connections of CT 641 are fully similar to CT 340, except that with CT 641 models
the back plane is equipped with an additional terminal strip X3 providing the relay connector:
9.2. Front Thumbwheel Switches
Moreover, the CT 641 models provide thumbwheel switches on the front panel, for simple and
easy setting of the cutting length.
This is how the front switches work:
Upon power-up the unit will read the thumbwheel settings and overwrite the internal
cutting length setting correspondingly, i.e. the system cuts the length set by the front
thumbwheels.
When during operation you change the thumbwheel setting, this will not affect the
cutting length until you apply a “Read Thumbwheel” command to the unit. You can
assign this command to either one of the front keys or to one of the Control Inputs, as
shown under sections 6.2.6 and 6.2.7
When the front thumbwheels are all set to zero, the controller will automatically use the
internal cutting length as entered by menu.
CT34002a_e.doc / Nov-15 Page 39 / 42
AC power supply :
24 V~ +/-10%, 15 VA
DC power supply :
24V- (17 – 40V), approx. 100 mA (+ encoders)
Aux. encoder supply outputs:
2 x 5,2 VDC, 150 mA each
2 x 24V DC, 120 mA each
Inputs :
2 universal encoder inputs
4 digital control inputs HTL (Ri = 3.3 kΩ)
Low < 2.5 V, High > 10 V, min. pulse width 50 µsec.
Counting frequency (per encoder) :
RS422 and TTL differential: 300 kHz
HTL single ended: 200 kHz
TTL single-ended: 200 kHz
Switching outputs (all models) :
Relay outputs :
(models CT641 only)
4 fast power transistors 5 - 30V, 350 mA (b)
Response time < 1 ms (a),
4 relays (dry changeover contacts) (b)
AC switching capability max. 250 V/ 1 A/ 250 VA
DC switching capability max. 100 V/ 1A/ 100 W
Serial link :
RS232, 2400 – 38400 Bauds
Analogue outputs :
0…+/- 10V (load max. 2 mA)
0...20mA (load max.270 Ohm)
Resolution 14 bits, Accuracy 0.1%
Overall response time < 1 ms (a)
Ambient temperature :
Operation: 0 - 45°C ( 32 – 113°F)
Storage: -25 - +70°C (-13 – 158°F)
Housing :
Norly UL94 – V-0
Display :
6 Digit, LED, high- efficiency red, 15mm
Protection class (front side only) :
Protection class rear side :
CT 340: IP65
CT 641: IP20 (with use of the plexiglass
cover part # 64026 also IP65)
IP20
Screw terminals :
Cross section max. 1.5 mm²,
Conformity and standards:
EMC 89/336/EEC: EN 61000-6-2
EN 61000-6-3
LV73/23/EEC: EN 61010-1
10. Specifications and Dimensions
(a) Continuous serial communication may temporary increase response times
(b) Diode or RC filtering is mandatory when switching inductive loads
CT34002a_e.doc / Nov-15 Page 40 / 42
96,0 (3.780’’)
110,0 (4.331’’)
4
4
,
0
(
1
.
7
3
2
)
1
0
,
0
(
.
3
9
4
)
8
,
0
(
.
3
1
5
)
91,0 (3.583)
9,0 (.345)
129,0 (5.079)
140,5 (5.531)
48,0 (1.890)
Dimensions of model CT340:
Panel cut out: 91 x 44 mm (3.583 x 1.732’’)
CT34002a_e.doc / Nov-15 Page 41 / 42
96,0 (3.780’’)
110,0 (4.331’’)
90,5 (3.563)
10,0
(.394)
8,0 (.315)
88,5 (3.484)
9,0 (.345)
129,0 (5.079)
140,5 (5.531)
9
6
,
0
(
3
.
7
8
)
18,5 (.728)
1
1
1
,
5
(
4
.
3
9
)
With optional plexi glass cover
for protection class IP65
(motrona part # 64026)
1
2
,
0
(
.
4
7
2
)
Dimensions of model CT641:
CT34002a_e.doc / Nov-15 Page 42 / 42
Panel cut out (b x h): 89 x 91 mm (3.504’’ wide x 3.583’’ high)
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