Control unit for Strip Thickness Gauges with nominal size setting by stepper motor FS4-PLC Operating Instructions FS4P-E1 erstellt am 15.4.2002 freigegeben am Bemerkungen Rev.1 Seiten: Name: Rietdorf Name:
measuring ++ controlling ++ recording ++ automation ++ documentation Content page Intended use of this machine... 2 Safety Precautions, please read carefully!... 3 Design and function... 4 Start-up and repairs... 7 Operation... 8 Nominal size selection / setting... 8 Safety note... 8 On strip motion of the gauge... 9 Errors... 10 Error messages... 10 Off strip motion of the gauge... 11 Automatic zero adjustment A0... 12 Coil change... 12 Service mode... 12 Automatic symmetry adjustment... 13 Quick off strip (optional)... 13 Notes... 14 Subject to change without prior notice Intended use of this machine This gauge must be used exclusively as a control unit for the individual Vollmer gauge it has be designed for and adapted to by the Vollmer company. It must be firmly installed in its intended position and electrically and electronically connected as intended by the Vollmer company. Any alteration might cause severe damage. 2 FS4-PLC Operating Instructions
FRIEDRICH VOLLMER Feinmeßgerätebau GMBH 58093 Hagen Verbandsstraße 60 ( 02334/507-0 Fax 02334/53015 Safety Precautions, please read carefully! This manual has to be handed to the machine operator, and one copy must be permanently available to operator and service personnel. Nobody is allowed to work on or with this gauge, before he has read and understood this manual. Feel free to call the Vollmer company in case of any questions (phone +49 2334 507 0). In addition, the operator has to read the instruction manuals for the other Vollmer devices, such as the VMF amplifier and the thickness gauge. They are part of the entire documentation and they contain safety relevant information which might not be included in this manual.. Check if the voltage on the model label is the same as the main supply voltage. Never connect the product to any power supply which has a different voltage than on the model label. Warning, Crushing Hazard! In many applications, this gauge has a hydraulic traverse unit. Such traversing units are very powerful and might cause severe injury. Before operating this device, you must read the safety precautions in the operating instructions manual of the gauge! The gauge control system has to be switched to the mode 'Service I', before anybody enters the danger zone close to the gauge. When operating in the standard mode ('Service 0') the gauge might rush back or forward unexpected and uncontrollable. Attention, risk of mechanical damage! Enter a new nominal value only as long as the gauge head is in the rear limit position. The gauge and or the mill might become severely damaged if a new nominal thickness value is read into the control electronics as long as the gauge is on strip or as long as the mill`s thickness control is in operation. Do not perform any manipulations on this product not described in this manual. Wrong handling might cause hazards for the user, and it terminates the instrument warranty period. Caution! Crushing Hazard by the traversing device of the gauge head! Before operating this device, you must read the safety precautions in the operating instructions manual of the gauge! This product may only be used if it is in a technically perfect condition. Any changes or defects which might affect the safety must be eliminated before the product is put into operation. Expose this product only to such environmental conditions as it is designed for. Stick to the notes in the technical documentation. This product is not designed for use in wet environments. Do not use this product in explosion hazardous areas. Before putting this product into operation and regularly during operation, check this product for damage. Defects of all kinds must be eliminated at once by authorized service personnel. The use of original spare parts and of additions from the manufacturer reduce the security hazard. Never operate this product if any cover is open or removed. Check all connections regularly and replace defective parts immediately. Operating Instructions FS4-PLC 3
measuring ++ controlling ++ recording ++ automation ++ documentation Design and function The FS4-PLC unit is a programmable control unit for Vollmer gauges, such as strip thickness gauges, gap sensors or position sensors on mills. In the following only strip thickness gauges are mentioned in order to make the reading easier. Each of the controlled gauges has one Vollmer measurement transducer whichs position may be shifted to different nominal size positions by a stepper motor. This is done to extend the measurement range of the gauge since the transducer itself has only a stroke of one or two millimetres, depending on the transducer type. The nominal size position to which the transducer has been shifted by the stepper motor forms a reference position and is not altered during the actual measurement. The transducer measures only the difference to this set nominal value. The different nominal values within a rolling program are usually automatically read into the FS4-PLC from an external control stand. However, it is possible to enter such data manually. The FS4-PLC controls the stepper motor which shifts the transducer to the selected nominal size. This is done by means of a high precision stepper motor and high precision spindles without any feedback from the measurement ram. The ram will not touch the material surface unless the gauge is in measurement position and a strip is in the mill. During the measurement, the VMF measurement amplifier indicates the difference between the measured actual thickness and the nominal size. The thickness data (together with additional data) are available on the outputs of the VMF amplifier. The functions of the gauge and of the connected VMF amplifier are described in separate manuals. These manuals are part of the Vollmer documentation. There are several gauge control keys on the control panel of the FS4-PLC. All these functions may be selected from external sources as well. Because the FS4-control unit features many parameters which may be set on site, it can be adjusted to meet virtually every individual situation. The FS4-PLC is an important element for the high reliability of the Vollmer measurement and control systems for strip processing machines. 4 FS4-PLC Operating Instructions
FRIEDRICH VOLLMER Feinmeßgerätebau GMBH 58093 Hagen Verbandsstraße 60 ( 02334/507-0 Fax 02334/53015 S7 H SP Mini Control unit for a Vollmer strip thickness gauge: An S7 type PLC is installed above the heating controller H. The SP-Mini motor power unit generates drive pulses to the stepper motor in the thickness gauge. This picture shows an example, the arrangement of the devices in the FS4-PLC unit may be different for individual applications. Operating Instructions FS4-PLC 5
measuring ++ controlling ++ recording ++ automation ++ documentation FS4-PLC as control unit of a Vollmer strip thickness gauge. Read the text for details. 6 FS4-PLC Operating Instructions
FRIEDRICH VOLLMER Feinmeßgerätebau GMBH 58093 Hagen Verbandsstraße 60 ( 02334/507-0 Fax 02334/53015 The sketch on the left shows the general design of the FS4-PLC control: The profibus feeds external signals into the S7. The CPU converts such signals so that they can be passed on by the interfaces, e.g. for traversing the gauge head back or forth. In addition, the S7 generates the signals for the VMF amplifier and the SP-Mini. Such commands may be entered at an external control stand and are transferred by the profibus or they may be entered manually at the FS4-PLC`s control panel. The VMF amplifier sums up the signals of the two transducers and passes the measurement value to the S7. The SP-Mini generates drive pulses for the stepper motor which shifts the adjustable transducer to the position of the selected nominal size. The SP MINI stepper motor power supply indicates the operation status by an LED (see arrow): green = OK, red = error, yellow = motor is operating. Start-up and repairs This unit must not be started up for the first time nor be repaired by other people than the Vollmer staff or specially trained (by Vollmer) staff of the customer. The information required for start-up and repairs can be read from the electric diagrams in the documentation. Operating Instructions FS4-PLC 7
measuring ++ controlling ++ recording ++ automation ++ documentation Operation The functions described in this section may be activated either manually at the control panel of the FS4-PLC or by external signals. Nominal size selection / setting Select the nominal size at the thumb wheel decade switch or put in an external signal to the S7. The last digit means 1 micron (1µm). The pushbutton "set nominal size" (german "Sollwert setzen") flashes as long as the selected value is different from the previously set nominal size. Press this pushbutton to read the new nominal size value into the electronics and to adjust the gauge to that new value. Now the stepper motor automatically sets the adjustable gauge transducer to the new nominal size position. Safety note Enter a new nominal value only if the gauge head is in the rear limit position without material in the measurement mouth. The gauge and or the mill might become severely damaged if a new nominal thickness value is read into the control electronics while the gauge is on strip or while the mill`s thickness control is in operation. 8 FS4-PLC Operating Instructions
FRIEDRICH VOLLMER Feinmeßgerätebau GMBH 58093 Hagen Verbandsstraße 60 ( 02334/507-0 Fax 02334/53015 On strip motion of the gauge This pushbutton is active if all conditions are fulfilled to enable the gauge traversing towards the strip. The thickness gauge can be moved on strip under the following conditions: - no signal emergency stop - signal strip tension is OK - no error signal from the pneumatic pressure detector - no error signal from the limit switch in the gauge`s measurement mouth - no error in the zero adjustment cycle A0 - light barrier is open - service mode switch is set to "Service 0" The thickness gauge is moved onto the strip by pressing the on strip pushbutton. The following functions are operated: Warning! Crushing hazard As long as somebody is in the danger zone close to the gauge, the gauge must be operated in the Service mode. No other operation mode is allowed. - magnetic valve thickness gauge on strip is switched on (gauge moves forwards and lamp on strip flashes slowly at a rate of one flash per second) - the two magnetic valves for diamond lifting, "DAV top and "DAV bottom", are switched on (measurement tips of the upper and lower transducer are pneumatically pulled in) - light barrier signals, that the gauge has reached the strip edge (infrared light beam is interrupted) 0,1 to 10 seconds (adjustable) after the light barrier was interrupted, the following functions are operated: - magnetic valve thickness gauge on strip is switched off (gauge stops) - the two magnetic valves for diamond lifting, "DAV top" and DAV bottom" are switched off (the measurement pressure springs in the transducers push the measurement tips of the upper and lower transducer against the strip surface) - the magnetic valve pneumatic guide rollers is switched on (upper guide rollers are pneumatically pushed down onto the strip with the adjusted working pressure) - the magnetic valve pneumatic diamond cooling is switched on (compressed air is blown against the measurement tips) - the control lamp on strip goes on - the signal in position, which enables the automatic control, is generated after a short time period for stabilizing (e.g. 1.3 seconds); the lamp "in position" goes on. Operating Instructions FS4-PLC 9
measuring ++ controlling ++ recording ++ automation ++ documentation Errors The gauge head is not enabled to be traversed forward if the light barrier is interrupted when the gauge is in its rear limit position. The lamp in the quit error pushbutton flashes to indicate the error. Other possible reasons for errors: - rear limit switch is defective - service function is on, i.e. the "service" switch is set to "I" - signal emergency stop is on - light barrier is dirty or defective (cable) - limit switch in the gauge measurement mouth is defective - no feedback from the compressed air pressure detector First eliminate the error reason(s) and then press "quit error". The lamp will only go off if all error reasons were eliminated before. Error messages The digital indication shows an error code if an error occurs: 9001 error Sp Mini not ready 9001 error Sp Mini error XXXX wrong input FM 353 (special error No.) 9004 data error FM 353 9005 reading error FM 353 9006 error VMF 2000 system not active 9007 error write command "speed" to FM 353 9008 error write command "enable regulator" to FM 353 9009 error write command "reference position" to FM 353 9010 error transducer holder not open during A0 9011 error motor moves to plus direction 1 mm 9012 error transducer control A0 9013 error transducer signal > 500µm FM 353 means the positioning device (to control the stepper motor) in the S7-PLC. 10 FS4-PLC Operating Instructions
FRIEDRICH VOLLMER Feinmeßgerätebau GMBH 58093 Hagen Verbandsstraße 60 ( 02334/507-0 Fax 02334/53015 Off strip motion of the gauge The thickness gauge moves off strip to its rear limit position, if: - the off strip pushbutton is pressed or - emergency stop is activated or - the limit switch measurement mouth is contacted by strip slipping away to the side or - strip tension breaks down The following functions are operated after the signal off strip : - control lamp "off strip" flashes - feedback control is switched off immediately - control lamp in position goes out - magnetic valves pneumatic diamond cooling" and "pneumatic guide rollers" are switched off (the cooling air jet is switched off and the upper guide rollers are released from a portion of their pneumatic pressure - the two magnetic diamond lifting valves DAV top and DAV bottom" are switched on (measurement tips of the upper and lower transducer are pneumatically lifted off the strip) - the magnetic valve gauge off strip is switched on (gauge moves back and the control lamp in the off strip pushbutton flashes slowly once per second) The following functions are operated after the gauge reached the rear limit position switch : - magnetic valve gauge off strip is switched off (gauge stops in rear limit position) - control lamp off strip turns to permanent light - DAV is switched off (transducer tips contact each other) Operating Instructions FS4-PLC 11
measuring ++ controlling ++ recording ++ automation ++ documentation Automatic zero adjustment A0 If the gauge is in the rear limit position, the A0 cycle can be started with "A0". Pressing of the A0 pushbutton (or external signal) starts these functions: - A0 key starts to flash in 1 second strokes during the A0 cycle - memory of the VMF measurement amplifier is erased by a pulse - analogue value of the VMF amplifier is used to move the upper transducer to zero - motor stops within the tolerance window (a few microns + and minus to zero) - VMF indicator is set to zero - FS4PLC counter is set to zero - stepper motor moves the adjustable transducer to the last valid nominal size - A0 key stops flashing The A0 cycle may also be performed with the gauge head in measurement position (on strip). In that case the automatic strip thickness control is disabled for the duration of the A0 cycle. Pressing the A0 key makes the gauge moving off strip into the rear limit position. There the A0 cycle runs as usual. After the zero adjustment the thickness gauge moves back on strip and the strip thickness control is automatically enabled. The A0 control lamp flashes if the system requires an A0 procedure, e.g. after Power On or after an error. No measurement is enabled unless a successful A0 cycle has been performed before. Coil change This signal terminates the data reading and starts the statistic evaluation for the finished coil. Regard the Safety Notes about the service mode which are printed in the Operating Instructions manual of the strip thickness gauge! Service mode Activating of the service mode (when all of the thickness gauges are in their rear limit position), switches off the following functions: - pneumatic diamond cooling - diamond lifting system DAV - strip tension monitoring - pneumatic guide rollers - measurement mouth limit switch 12 FS4-PLC Operating Instructions
FRIEDRICH VOLLMER Feinmeßgerätebau GMBH 58093 Hagen Verbandsstraße 60 ( 02334/507-0 Fax 02334/53015 - light barrier - compressed air pressure detector - emergency stop Now the thickness gauge can be moved on and off strip by inching service. The service mode remains active (even if the service switch is turned off) until the gauge was brought to its rear limit position. Automatic symmetry adjustment Automatic symmetry adjustment can only be operated when the Service mode is on. First set the gauge to the nominal size zero. By switching sym on this type of the FS4 PLC switches the pneumatic valves for the diamond lifting alternating for the top and the bottom side. A detailed description about the service mode and the automatic symmetry adjustment is in the Operating Instructions manual for the gauge and in the instruction manual for the VMF amplifier. Quick off strip (optional) With this option the gauge is able to move back faster than in normal mode because of an additional bypass valve. This function is activated in following situations: - emergency stop is activated - breakdown of strip tension - measurement mouth limit switch has been actuated Operating Instructions FS4-PLC 13
measuring ++ controlling ++ recording ++ automation ++ documentation Notes 14 FS4-PLC Operating Instructions