Operating Instructions / New Gauge Conception. 1. Connection diagram 1 2. Gauge controlling by OP Heating 6 4. ET200 X 8 5.

Transcription

1 Operating Instructions / New Gauge Conception agen, Mar Content Page 1. Connection diagram 1 2. Gauge controlling by OP Heating 6 4. ET200 X 8 5. Service Connection diagram (except supply for VMF and Gauge) Cabinet OP 7 ET 200X Gauge PLC VMF 1000 Profibus Supply VMF 1000 OP 7 ET 200X Gauge This diagram shows the new conception of a Vollmer gauging system. In the following, the manual refers only to the most important components, the OP7 and the ET 200X. OP7: compact control terminal with keypad and text display FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 1

2 ET 200X: field unit with 8 digital inputs 2 extension modules with 4 digital outputs each (2A) pneumatics module with 16 digital outputs The Siemens operator panel OP7 is the main control unit for all gauge functions. The main features are: nominal size selection and indication motor control data indication (motor position) temperature selection and indication gauge on strip/off strip transducer zero setting (A0) service on/off transducer symmetry adjustment selection of the measurement depth (distance from strip edge) in ms or mm error message indication in plain text All the functions are software based. There are no additional hardware pushbuttons, lamps or switches installed in the electronic cabinet or at the gauge. Display Function Keyboard forw. backw. Number Keyboard Interface Connection fig 1: OP7 FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 2

3 2. Gauge controlling by the OP7 The overview in the appendix show the menu structure of the OP7. Page one and two are of main interest for potential customers as they show the adjustment features of the OP7. Page 3 was made for the member of the service staff. It shows gauge control system data. Definitions: The display changes depending on the operation mode. In the "normal" mode, it shows the entered nominal size, the motor control data and the gauge temperature. In the "service" mode, the basis mask shows only the message "Service Mode". Other messages are displayed in a similar way. Pressing the ESC key switches back to the main mask. Depending on the menu level from where the switching begins, ESC might need to be pressed for several times. Pressing of the ENTER key switches from the main mask into the input level. The OP7 switches up for one menu level automatically once every three minutes. Pressing the ACK key acknowledges an error message in the OP7 display. The functions keys F1, F2, F3 and F4 are context based, i.e. the function changes depending on the display mode. Their current function as described in the display just above the key. The keys K1, K2 and K3 have are permanent keys, i.e. their functions do not change and they are operational at any time. The function keys are used to navigate through the submenus. The signs << and >> indicate, that the current level offers more options. Pressing one of those two functions keys switches to the following display. Some functions, which are only seldom used, are password protected. Examples are the Heating submenu and the Service mode. The password is 100. Entering this password unlocks the option for three minutes. If there is no entry within that time, the option is automatically locked again. For an entry, the password needs to be entered anew. Here are the main functions: Display after Mains On (switch ON at the electronic cabinet): The A0 diode flashed at a rate of approx. 2 Hz after the system was switched on. Pressing of the A0 key starts the automatic zero setting. The A0 LED is on during the A0 routine and the display shows the mask of the A0 operation mode. It includes the motor control data (motor position) and the transducer data (measurement value). After the zero setting was finished, the LED goes off and the display switches into the "normal" mode. Selection of the control mode: After the system start, a decision is required, if the gauges are controlled by the OP7 or vie the profibus. The offered selection may be altered by: pressing ENTER in order to switch from the main mask to the input level pressing the SERVICE key pressing the << or >> key to flip through the menu to the OPERATION option press the corresponding function key to select between OP7 and PROFIBUS The following description requires that the OP7 control mode is selected. Nominal size input: FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 3

4 press ENTER in order to switch from the main mask to the input level press NOMINAL SIZE (F2) enter the nominal size in microns by the keypad quit the nominal size by pressing ENTER press START (F4) to read the nominal size into the gauge Note: in the INCH version of the software, the nominal values are entered as inch. The decimal point must be entered as well. Preconditions for the nominal size input: no error Gauge on strip / off strip: Automatic mode (normal mode) pressing Forward for a moment, moves the gauge on strip. The gauge detects the strip edge and stops after the preset distance or time (see under Selection of the measurement depth) Inching service (in the service mode) The gauge is moved forward or backward as long as the key is pressed or until it reaches the limit stop. Caution: Only trained staff is allowed to operate the gauge in the inching service, because in this mode all interlocks are open. The menu option HLP has a submenu which contains a list of all the preconditions which have to be fulfilled before the gauge is enabled to be moved forward. All points must be flagged OK. If one or more flags are NOT OK, the gauge traversing is blocked. If so, the reason needs to be found and eliminated before the gauge traversing is enabled. Automatic zero setting (A0): The A0 Start key starts the automatic zero setting. It can be started from two situations: Gauge in rear limit position If the gauge is in the rear limit position and if no error is detected, the A0 routine can be started. Gauge on strip (in measurement position) In the A0 key is pressed when the gauge is in measurement position, the gauge is traversed into the rear limit position where the A0 routine is performed. After the zero setting the gauge is automatically traversed into the measurement position. See under "Display after Mains On" for a detailed description of the zero setting cycle. FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 4

5 Preconditions for the enabling of A0: no error gauge in measurement position or in rear limit position. To select the service mode: 1. press ENTER in order to switch from the main mask to the input level 2. press SERVICE to reach the service level 3. press ON to start the service mode 4. message: INVALID PASSWORD LEVEL enter pass word 100 into the keypad and confirm with ENTER 7. press ON to start the service mode 8. press OFF to quit the service mode Preconditions for the starting of the service mode: Gauge in rear limit position Transducer symmetry adjustment Switch gauge to Service mode (see above) In the Service submenu, use the >> or << keys to find the SYMM option Start the symmetry adjustment by the ON/OFF key After symmetry was adjusted successfully, the PLC does automatically switch off this mode To stop the symmetry adjustment, press ON/OFF again. The measurement amplifier needs a separate setback to normal mode. This can be done e.g. by pressing the key RESULT/ERGEBNIS Preconditions for the symmetry adjustment: gauge in service mode nominal size Inch selection of the measurement depth (in ms or mm): press ENTER in order to switch from the main mask to the input level press Meas. Depth enter nominal value for meas. depth in ms (depending on gauge type) press ENTER to confirm selected measurement depth Parameters: The PARAMETER option in the SERVICE menu is only used for the first start-up at the factory. The parameters are set by Vollmer and should not be changed any more. Parameter 1: maximum nominal size This parameter is set to the maximum nominal size (e.g. strip thickness) which the gauge is able to measure. The size depends on the gauge type. Parameter 2: measurement depth FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 5

6 The measurement depth can be set in two ways, depending on the gauge type. For standard type gauges, the measurement depth is set in milliseconds. The time starts to run when the light barrier in the gauge head crosses the strip edge and the gauge stops when the time is over. Some gauge have a position transducer, which measures the distance when they are traversed along the slidebase. For such gauges, the measurement depth is set in millimetres. The gauge is traversed until the light barrier is at selected distance from the strip edge. Vertical Guide: The sub menu >vertical guide< in the menu >service< is for an adjustment of the pneumatic vertical guide. The factor takes effect on the sensitivity. 3. Heating The heating control is completely integrated into the S7 PLC. Two control elements are installed in the software: two point regulator self optimising regulator The standard type two point regulator works in the classic way. It regulates the measurement temperature according to the preset nominal temperature and the preset hysteresis value. the regulation algorithm is easy understandable, it is always predictable when the heating goes on or off. no training required The self optimising regulator can be "trained" to suit the individual gauge. This is done by the Optimisation option in the Heating submenu. Pressing the key starts the heating and measures the time until the temperature sensor measures a temperature rise of 1 C. That period of time is stored and used as default value for the heating regulation. This routine needs to be performed only once during the first system start-up. To avoid errors, it must be done on a cold gauge, i.e. the heating was not on within the previous twelve hours. the regulator produces only minor overshoot optimum regulation result Heating adjustment features: Heating on/off Allows to switch the heating on or off Optimisation on / off Optimisation (training) of the heating regulator to find the optimum heating rate for the individual gauge (see under "Heating start-up" for details). Nominal temperature Input of the nominal temperature in C. Press ENTER to confirm the entry. Offset Offset = indicated temperature - actual temperature Enter the difference between the temperature indicated by the OP7 and the real temperature at the gauge head. The calculated offset must be positive, if not the temperature measurement is wrong Two point regulator If the two point regulator is activated, the heating regulation switches to a simple two point regulation. It is not recommended, to activate this mode after the optimisation (see below) has been performed. FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 6

7 Hysteresis here a switching threshold is entered. The standard value for the hysteresis is 0,3 C. The hysteresis must not be set to a smaller value. Factor (only valid for self optimising regulator) no input required Pause time (only valid for self optimising regulator) is calculated automatically, no input required Start-up of the heating: The heating can be started for the first time after the entire system has been installed and is operational. The first action is an optimisation routine. This is performed like described in the following: In the submenu Service press >> or << to reach the Heating option. Call up the Heating menu by pressing the corresponding function key. Flip through the options by pressing >> or << to reach the Optimisation option. Start the routine by pressing the corresponding function key. Note: This routine needs to be performed only once during the first system start-up. To avoid errors, it must be done on a cold gauge, i.e. the heating was not on within the previous twelve hours. The optimisation is finished after the temperature indication has risen for 1 C (after max. 30 minutes). After the heating was switched on, it takes about eight hours until the gauge is thoroughly heated. The optimised regulator is then able to keep the temperature within a small tolerance range. 4. ET 200X The ET 200X is the hub in the new pneumatic cabinets. The cabinets are much smaller now and they are installed directly on the gauge. Only two cables lead from the electronic cabinet to the pneumatic cabinet, one for the power supply and one for the profibus. There are no terminals any more, so that installation and service is much easier now. FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 7

8 Die ET 200X unit comprises a basis module with eight inputs (each plug has two inputs), two 2A output modules with single connected plugs and a pneumatics interface with a valve unit made by Festo. fig 2: ET 200X basis module The basis module has connectors for the profibus and for the power supply on its left side. The sockets X1, X2, X3 and X4 are the inputs. Each of the plugs is connected to two inputs. Diodes on the top of the basis module indicate the voltage supplied, bus errors (BF), operating mode of the unit and 5V supply. fig 3: 2A output module The extension module is receives its power via the rear panel bus. Diodes indicate the current switching status of the outputs. FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 8

9 fig 4: Pneumatic interface module The pneumatic interface module does also receive its supply vie the rear panel bus. Like at the output module, diodes indicate the current switching status. A Festo valve unit is put on top of this module. This unit is able to control the switching of up to 16 valves. 5. Service FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 9

10 The following sections contain some information for member of the service staff: Replacement of a defective OP7 Replacement of a defective ET 200X module Connection of the profibus lead Cleaning of the OP7 Replacement of a defective OP7 Software: Mechanic: If the OP7 is replaced on site, the new OP7 must have correct software loaded. The software is individually made for each application. The set-up of the operator panel has to be done by a trained specialist. The dimensional data are displayed in the following: dimensions: front view side view Display Function Keyboard Number Keyboard top view interface connections panel cutout supply voltages fig 5: design of the OP7 When replacing an OP7, make sure that the label strips for the function keys and for the control keys are taken from the old unit (pull strips out to the side) and inserted into the new one. electric: As shown above, the OP7 has only three electric connectors. IF1B: connector for the profibus FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 10

11 IF1A: connector for the programming device -/+: 24V DC voltage supply Replacement of a defective ET 200X module Defective extension modules, such as output module or pneumatic module, can be easily replaced by a spare module with exactly the same part number. There is no need for any adjustment by software or by switches. If the basis module is defective, in can be replaced by a spare module with exactly the same part number. The DIP switches under the connectors for the power supply and for the profibus must be set in the same way as they were at the old module. Those switches set the profibus address and the terminator resistance. Connection of the profibus lead If a connector of the profibus lead is replaced, the DIP switches have to be set in the same way as they were before. Cleaning of the OP7 The front of the terminal can be cleaned with a damp cloth. The unit has to be switched off during the cleaning so that no erratic inputs are made. Use only water and some washing-up liquid, but never aggressive cleansing agents or scouring agents. FFSS44- -PPLLCC,,, OOPP77 VVeer rssi iioonn OOppeer raat ttoor r Maannuuaal ll VV VVMFF ddoocc 11