Operating Instructions ERM Control Unit
Contents
1. 6057 758 101 2005 02 24 to 36 V Operating modes Voltage supply ground 1 2 actual sensor 7 5 grinder 8 Nominal traction sensor 7 5 grinder 9 Set key 11 17 18 Hysteresis brake 16 6 Set actual i a G 12 ZF electronic unit ERM B 9 Nominal traction 5 8 1 2 27 16 6 Hysteresis brake clutch 015232 Operating modes 3 3 3 Technical instructions LED Power ON O contr flashes until the setting procedure is complete DIL switch setting DIL switches 1121314151617 Controlled with sensing 1lololo Unit size coding clutch brake 1lololo see page 18 DIL switch setting Jumper position Jumper position 2 and 3 see 1 4 page 13 can activate further functions 6057 758 101 2005 02 28 Electronic control unit ERM 3 3 4 Startup 1 The electronic control unit is disconnected 2 Make sure that voltage is within the range given under 1 Technical Data see page 6 3 Check polarity plus minus CAUTION Unpermitted voltage and polarity may damage the installation 4 Switch off operating voltage 5 Connect the ERM 6 Switch on operating voltage Power LED must light up O Contr LED must flash Electronic control unit ERM 7 Setting of nom value potentiometer Voltage values Up and Upi measured at random poten2. e Operating mode closed loop control The DIL switches must be set to suit unit size y 7 a Coding Type nomi nomi Y Y Y Y see page 18 oak DIL switch nal nal PD PI and PID are available for position and force 1 Alea control current torque COSE P 2lalalsle 7is A Nm The I portion can be blocked by stop input Thus the rage FKU 03 T TA last controlled torque is maintained when the unit is o lalo l 3 7 5 stopped PP 010 EKU 3 5 3 0 0101110 EKU 10 8 12 0 Operating mode closed loop control 01110 EBU 0 1 0 4 0 15 112131415161718 DIL switch oli lailo EBU 0 3 075 04 YEN O O PD for position control 110 EBU 25 1 1 Y 1 1 O Pl for force control 010 0 EBU 3 25 3 3 e g with mech compensator 0 EBU 10 5 12 0 YY 1 1 Pl for force control 0 1 0 EBU 30 2 2 39 0 e g with no travel tension sensor or freely olo EBU 60 G 5 82 0 programmable ola To EBU 200 G 2 2 268 0 YIYIYIY 11011 PID for position or force control 0 EBU 250 1 J 0 6 01011 EBU 500 3 4 2 5 0 1 EBU 1000 10 9 9 0 LIA EBU 2000 30 2 26 0 2 2 Coding clutch brake ola EBU 500 30G 4 25 0 011 EBU 1000 100G 9 90 0 NOTE 7 QT EBU 2000 300G 2 260 0 With DIL switches 1 4 the ERM control unit can be set to olla EBU 2000 600G 27 520 0 the corresponding clutch or brake 6057 758 101 2005 02 18 Electronic control unit ERM Description 2 3 Controller for transfer function PD
3. 30 to 70 C DIN IEC 68 part 2 30 IP 30 19 7 TE plug in module 18 pin pull off screw type terminal within the scope of supply 0 6 kg The screw type terminal block is not suitable for bus assembly Make sure that connecting cables are long enough or that the screw type terminal block on the rear of the assembly rack is accessible Electronic control unit ERM Technical Data Installation dimensions 35 015242 6057 758 101 2005 02 7 Technical Data 1 2 Circuit board removal and installation Removal 1 Switch off operating voltage CAUTION If the operating voltage is not switched off product and system can be damaged 2 Remove terminal strip 2 from plug connector 3 3 Remove screws 1 4 4 Carefully pull board out of the rack without tilting 6057 758 101 2005 02 Electronic control unit ERM Installation 1 Carefully insert board into rack guiding slot without tilting 2 Tighten screws 1 4 so that the cooling attachment on the board contacts the metal rack and thus ensures optimum heat dissipation NOTE Do not exceed permissible tightening torque to avoid board damage 3 Make sure that operating voltage is switched off CAUTION If the operating voltage is not switched off product and system can be damaged 4 Introduce terminal strip 2 into plug connector 3 CAUTION Contacts must not be damaged otherwise perfect
4. Operating instructions ZF Electronic Control Unit ERM 6057 758 101b Subject to alterations in design Copyright by ZF The present documentation is protected by copyright Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documen tation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted Printed in Germany ZF Friedrichshafen AG MC C 2001 03 Issue 2005 02 Companies repairing ZF units are responsible for their own work safety To avoid injury to personnel and damage to products all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to Before starting work mechanics must familiarize them selves with these regulations Personnel required to carry out repairs on ZF products must receive appropriate training in advance It is the responsibility of each company to ensure that their repair staff is properly trained 6057 758 101 2005 02 Safety instructions The following safety instructions appear in this manual NOTE Refers to special processes techniques data use of auxiliary equipment etc CAUTION This is used when incorrect unprofessional working practices could damage the product A DANGER This is used when lack of care could lead to personal injury or death General Information Read this manual carefully before starting any tests or repair work
5. PIN connection Voltage supply plus 24 36 V 17 18 Voltage supply ground 1 2 Actual traction sensor 7 5 grinder 8 Nominal traction sensor 7 5 grinder 9 Stop key 10 17 18 Hysteresis brake 16 6 6057 758 101 2005 02 24 to 36 V Stop ZF electronic unit ERM 413 7 AH 9 Nominal traction 5 Actual 8 traction ot Hysteresis brake 015232 clutch 35 Operating modes Electronic control unit ERM 3 5 3 Technical instructions 3 5 4 Startup LED Power ON 1 The electronic control unit is disconnected Feedb ON 2 Make sure that voltage is within the range given under Stopping the installation Stop contact blocks I portion 1 Technical Data see page 6 not necessary for PD position control 3 Check polarity plus minus Sampling rate 100 Hz 10 ms CAUTION Unpermitted voltage and polarity may damage the DIL switch setting DIL switches installation 112131415161718 Operating mode closed loop control 1 1 4 Switch off operating voltage Unit size coding clutch brake ala 5 Connect the ERM see page 18 Controller transfer function see page 19 al 6 Switch on operating voltage DIL switch setting Power LED and Feedb LED must light up 7 The installation is ready for operation Jumper position Jumper positions 2 and 3 see 1 4 page 13
6. CAUTION Pictures drawings and components do not always represent the original object but are used to illustrate working procedures Pictures drawings and components are not to scale Conclusions about size and weight should not be drawn even within a complete illustration Always follow the working steps as described in the text After completion of repair work and testing skilled staff must satisfy themselves that the product is functioning correctly 6057 758 101 2005 02 1 1 1 2 1 3 1 4 1 5 2 1 2 2 2 3 3 2 3 3 Technical data ii Technical data installation dimensions Circuit board removal and installation Circuit board configuration PIN ASSIGNMENT ssaa deka a en ara een eee Ses Summary of pin assignment Description General configuration Coding clutch brake Controller for transfer function Operating modes Operating mode open loop current 3 1 1 Function diagram 3 1 2 Pin assignment 3 1 3 Technical instructions 3 1 4 Startup Operating mode open loop torque 3 2 1 Function diagram 3 2 2 Pin assignment 3 2 3 Technical instructions 3 2 4 Startup Operating mode controlled with sensing 3 3 1 Function diagram 3 3 2 Pin assignment 3 3 3 Technical instructions 3 3 4 Startup 6057 758 101 2005 02 10 12 14 16 16 18 19 3 4 3 5 3 6 4 Table of contents Operating mode cont
7. can activate further NOTE functions Should the installation not function properly consult 4 Identification and causes of failure corrective action see page 38 6057 758 101 2005 02 36 Electronic control unit ERM 3 6 Additonal functions max power zero power Imax Imin Clutch power flow can be influenced irrespective of operating mode Zero or max power for ERM possible depends on size of unit connected Optional limitation of max power by MobiDig 200 program Application Use Max power e g for emergency stop Zero power e g for start up Activation of additional functions Jumper on ERM board must be in Pos 2 Pos 1 must not be connected cf 1 4 Jumper position Input for max power function Pin 15 Input for min power function Pin 14 Ground Pin 1 or 2 Each function remains active as long a signal is present on input low level cf 1 1 Technical data 6057 758 101 2005 02 37 Operating modes Failure identification 4 Identification and causes of failure corrective action Electronic control unit ERM Failure identification Causes Corrective action LED contr flashes operating mode controlled with sensing gt Repeat setting procedure see page 28 LED contr flashes operating mode controlled with calculation gt Repeat setting procedure see page 33 Power LED does not light up N
8. for position control Coding CN L switch 21314Isle 7is PI for force control Coding e g mech compensator gJ L switch PI for force control Coding e g no travel tension sensor L switch 21314Isle 7is PID for position or Coding force control SiL switel 112131415161718 017601 6057 758 101 2005 02 19 Operating modes Electronic control unit ERM 3 Operating modes 31 Operating mode open loop current 3 1 1 Function diagram ZF Hysteresis brake eristic Roller 015236 015234 Nominal 10V traction 6057 758 101 2005 02 20 Electronic control unit ERM Operating modes 3 1 2 Pin assignment Designation PIN connection Voltage supply plus 24 36 V 17 18 Voltage supply ground 1 2 Nominal traction sensor 7 5 grinder 9 Hysteresis brake 16 6 24 to 36 V 12 ZF electronic unit ERM Hysteresis brake 4 clutch 015235 6057 758 101 2005 02 21 Operating modes 3 1 3 Technical instructions LED Power ON Control Current is set by the electronic system in accordance with the nominal value input DIL switches 112131415161718 DIL switch setting DIL switch setting Jumper position 2 see 1 4 page 13 can activate furthe
9. func tioning of the system is not ensured Electronic control unit ERM Technical Data 015239 6057 758 101 2005 02 9 Technical Data Electronic control unit ERM 1 3 Circuit board configuration Designation Function LED 1 Power Supply voltage is applied and ERM program is ready LED 2 Feedb Closed loop control operating mode i e DIL switch position 5 and 6 1 LED 3 e sensing operation DIL switch position 5 1 and 6 0 or D Contr e calculation operation DIL switch position 5 0 and 6 1 e LED Contr flashes if the setting procedure has not been carried out in the operating mode calculation or sensing Connection for diagnostic unit Diagnostic connector for ZF MOBIDIG tester cable acc to ISO 9141 Jumper For function selection e g feed rate interruption emergency brake Fuse DIL switches Fine wire fuse 4 A medium time lag fuse Setting of various operating modes and unit sizes Program memory ncludes microprocessor operating program Data memory Contains operating parameters Terminal strip 18 pin 6057 758 101 2005 02 10 Electronic control unit ERM Technical Data Program memory DIL switches Cooling attachement Fuse 12345678 OPEN 017182 Connection for diagno
10. ground current return cable measurement input clutch brake max 2 55 A depending on unit size voltage output 10 V 0 8 V DC max load 20 mA load impedance Ra min 500 Q voltage input actual value 0 to 10 V input resistance Rj 200 kQ Input may also be supplied by external analog sources provided the voltage refers to ground PIN 5 and the max value does not exceed 10 V 6057 758 101 2005 02 14 PIN 10 11 12 Electronic control unit ERM Function voltage input nominal value 0 to 10 V input resistance Rj 200 kQ Input may also be supplied by external analog sources provided the voltage refers to ground PIN 5 and the max value does not exceed 10 V digital input stop input resistance 4 7 kQ input current 5 to 8 mA Umax operating voltage Function is maintained as long as the signal is on digital input set push button input resistance 4 7 kQ input current 5 to 8 mA Umax operating voltage frequency input fn roller speed frequency 3 to 1000 Hz input resistance 3 3 kQ pulse 0 5 ms interpulse period 0 5 ms input resistance 3 3 kQ Electronic control unit ERM Technical Data PIN Function PIN Function 13 frequency input fy feedrate 16 current output clutch brake frequency 3 to 1000 Hz max 2 55 A depending on unit size input resistance 3 3 kQ NOTE Limit for EBU 2000 pulse 0 5 ms interpulse period 0 5 ms inpu
11. dance with the nominal value input DIL switch setting DIE switches 11213141516l718 Unit size coding clutch brake see page 18 DIL switch setting Jumper position Jumper position 2 see 1 4 page 13 can activate further functions 6057 758 101 2005 02 25 Operating modes 3 2 4 Startup 1 The electronic control unit is disconnected 2 Make sure that voltage is within the range given under 1 Technical Data see page 6 3 Check polarity plus minus CAUTION Unpermitted voltage and polarity may damage the installation 4 Switch off operating voltage 5 Connect the ERM 6 Switch on operating voltage Power LED must light up 7 The installation is ready for operation NOTE Should the installation not function properly consult 4 Identification and causes of failure corrective action see page 38 Operating modes 3 3 Operating mode controlled with sensing 3 3 1 Function diagram ZF Hysteresis brake 3 EET act Roller current A 015233 Nominal traction 6057 758 101 2005 02 26 Electronic control unit ERM U actual 015236 Sensor zero position equals 0 V as shown by the broken line sensor value 017181 Electronic control unit ERM 3 3 2 Pin assignment Designation Voltage supply plus 24 36 V PIN connection 17 18
12. e it can be stored in E2PROM The stored reference value is deleted when another opera ting mode is selected open loop control or closed loop control Production speed and nominal traction may be altered even during operation Operating mode controlled with sensing 1121314151617181DIL switch YIYIY Y 1 0 Unit size coding characteristic e Operating mode controlled with calculation The DIL switches must be set to suit unit size Y Y Y Y see page 18 Setting procedure e approach maximum roller e push set key when production speed is reached 6057 758 101 2005 02 Description NOTE If a frequency lt 3 Hz is already reached during a setting procedure no reference values will be transferred LED 3 continues flashing Frequency range 3 1000 Hz Stored reference values are deleted when another opera ting mode is selected open loop control or closed loop control e release set key reference values for max is accepted Production speed and nominal traction may be altered even during operation Operating mode controlled with calculation 1 2 3 4 5 6 7 8 DIL switch YIYIY TY 0 1 Unit size coding characteristic Description Electronic control unit ERM
13. es 1 2 3 4 5 6 7 8 Filter constant 0 1 Controlled with calculation 0 1 Unit size coding clutch brake see page 18 011 DIL switch setting Jumper position Jumper position 1 or 2 see 1 4 page 13 can activate further functions 3 4 4 Startup 1 The electronic control unit is disconnected 2 Make sure that voltage is within the range given under 1 Technical Data see page 6 6057 758 101 2005 02 Operating modes 3 Check polarity plus minus CAUTION Unpermitted voltage and polarity may damage the installation 4 Switch off operating voltage 5 Connect the ERM 6 Switch on operating voltage Power LED must light up O contr must flash 7 Set max roller speed and production speed gt 3 Hz 8 Push set key 9 Release set key Reference is accepted contr lights up 10 Installation is ready for operation NOTE Should the installation not function properly consult 4 Identification and causes of failure corrective action see page 38 Operating modes 3 5 Operating mode closed loop control 3 5 1 Function diagram lt q O Dancer es traction ZF Hysteresis brake Nominal 015230 traction 6057 758 101 2005 02 34 Electronic control unit ERM CIR 015231 Electronic control unit ERM 3 5 2 Pin assignment Operating modes Designation
14. esis brake clutch 17 18 11 ZF electronic unit ERM 16 Nominal traction 6 015238 6057 758 101 2005 02 31 Operating modes 3 4 3 Technical instructions LED Control Sampling rate Detection of web tear 6057 758 101 2005 02 Power ON O contr flashes until the setting procedure is complete updating of frequency 10 Hz 100 ms ERM offers output signals for roller and feed stoppage f lt 3 Hz which are evaluated and possibly identified as web tear by a machine controller Terminal 14 voltage if roller speed frequency lt 3 Hz Terminal 15 voltage if feed rate frequency lt 3 Hz see jumper position measured on PIN 17 18 32 Compensation of friction Determination of potentiometer voltage for the friction factor Electronic control unit ERM With minor traction installation friction may be relatively high compared to the brake torque needed This must be considered when calculating the brake torque The friction factor is the result of the relation between friction torque and nominal torque and is expressed as voltage value and set by an additional potentiometer at terminal 8 friction torque Uterminal 8 10 nominal torgue Electronic control unit ERM Setting of DIL switches Adjustable filter constant Filter time 7 8 New condition 0 5 sec ojo 2 5 sec 0 1 1 5 sec 1 0 0 2 sec 1 1 DIL switch
15. o be set e Operating mode open loop control current This operating mode is set by the manufacturer i e it is not necessary to change the DIL switch positions Current is set and kept constant in accordance with the nominal value input Operating mode open loop control current 1121314151617 8 DIL switch 0lololo1o1o as supplied 6057 758 101 2005 02 16 Electronic control unit ERM e Operating mode open loop control torque The DIL switches must be set to suit unit size Y Y Y Y see page 18 Torque is set and kept constant in accordance with the nominal value input Hereby the interdependence of the nominal voltage value torque is subject to approximate linear distribution Operating mode open loop control torque 1121314151617181DIL switch Y 0 0 Unit size coding characteristic Operating mode controlled with sensing The DIL switches must be set to suit unit size Y Y Y Y see page 18 Setting procedure e sense maximum roller e push set key e release set key reference value for max is accepted NOTE Data are stored in non volatile memory data are not erased when the supply voltage is switched off Electronic control unit ERM The reference value for the max is not erased when the supply voltage is switched off It can therefore be used when the ERM is fitted i
16. o operating voltage or too low gt Check operating voltage ERM fuse is defective gt Replace defective fuse Program does not run correctly gt Consult ZF All 3 LED lights will flash sequentially Operating voltage too low or too high gt Check operating voltage Reference voltage too low Short circuit or interruption at current output or coil is bridged gt Check load resistance gt Correct short circuit interruption Missing size gt see operating mode setting of DIL switches see page 18 6057 758 101 2005 02 38
17. r functions Jumper position 6057 758 101 2005 02 22 Electronic control unit ERM 31 4 Startup 1 The electronic control unit is disconnected 2 Make sure that voltage is within the range given under 1 Technical Data see page 6 3 Check polarity plus minus CAUTION Unpermitted voltage and polarity may damage the installation 4 Switch off operating voltage 5 Connect the ERM 6 Switch on operating voltage Power LED must light up 7 The installation is ready for operation NOTE Should the installation not function properly see 4 Identification and causes of failure corrective action see page 38 Electronic control unit ERM Operating modes 3 2 Operating mode open loop control torque 3 2 1 Function diagram ZF Hysteresis brake Tensi Roller Ty 015243 Nominal 9V traction 6057 758 101 2005 02 23 Operating modes 3 2 2 Pin assignment Electronic control unit ERM Designation PIN connection Voltage supply plus 24 36 V 17 18 Voltage supply ground 1 2 Nominal traction sensor 7 5 grinder 9 Hysteresis brake 16 6 6057 758 101 2005 02 24 to 36 V ZF electronic unit ERM 9 Nominal traction 5 8 Hysteresis brake clutch 015 235 24 Electronic control unit ERM 3 2 3 Technical instructions LED Power ON Control Torque is set by the electronic system in accor
18. rolled with calculation 30 3 4 1 Function diagram 30 3 4 2 Pin assignment 31 3 4 3 Technical instructions 32 3 44 Startup Women bind aoe Mana aon oma 33 Operating mode closed loop control 34 3 5 1 Function diagram 34 3 5 2 Pin assignment 0 00 eee 35 3 5 3 Technical instructions 36 3 94 Sta TUP ia Hoon an ane Naa 36 Additional functions max power zero power 37 Identification and causes of failure corrective action snur 38 Technical Data 1 Technical data 11 Technical data installation dimensions Nominal direct voltage for ZF hysteresis clutches and brakes at nominal torque and a coil temperature of 120 C Permissible residual ripple Operating voltage range Open circuit power consumption Maximum current input depending on unit size Fuse Voltage output Frequency input 30 V DC 1 5 V 24 V to 36 V DC lt 150 mA 2 8A fine wire fuse 4A medium time lag fuse 10 V 0 8V 20 mA Ra min 500 Q input resistance Rg 3 3 kQ Switching threshold low to high gt 11 5 V DC Switching threshold high to low lt 4 0 V DC 6057 758 101 2005 02 Electronic control unit ERM Ambient temperature Storage temperature Humidity class Safety class according to DIN 40 050 Rack Connection Weight NOTE 0 to 50 C
19. stic unit Microprocessor Jumper Data memory E2PROM Terminal strip 6057 758 101 2005 02 11 Technical Data Electronic control unit ERM 1 4 Pin assignment 24 V to 36 V Stop set 015241 Alternative function Web tear recognition Example for external analog input e g SPS PIN 17 18 24 V to 36 V 6057 758 101 2005 02 12 Electronic control unit ERM NOTE The electronic control unit does not require the potentiometer to fulfill any particular requirements However mechanical require ments regarding installation need to be considered Recommendations for potentiometer Resistance value 1 KQ 47 KQ Type magnetoresistive potentiometer for voltage input nom value also wire potentiometer can be used Jumper Position Appropriate function is activated by inserting a jumper Vids supplied standard functions tear recognition friction compensation 1e 2 terminal 14 current zero function terminal 15 current max function 3 Nterminal 8 actual 0 5 V instead of 0 10 V NOTE Pos 1 and 2 must never be connected simultaneously 6057 758 101 2005 02 13 Technical Data Technical Data 1 5 PIN aoa ar N e Summary of pin assignment Function ground ground no assignment no assignment analog
20. t resistance 3 3 kQ a7 Si Sean 3 4 Mika ot toe bab max current 2 8 A depending on unit size 14 output roller speed output voltage 24 V DC max load 50 MA max load impedance 10 kQ A suppressor diode must be used with inductive load no varistor input current zero load current 1 to 2 mA For functions consult relevant operation mode Function is maintained as long as the signal is on 18 voltage supply 24 V to 36 V max current 2 8 A depending on unit size 15 output feedrate output voltage 24 V DC max load 50 mA max load impedance 10 kQ A suppressor diode must be used with inductive load no varistor input current max load current 1 to 2 mA NOTE For functions consult relevant operation mode Gold plated contacts are recommended for pushbutton Function is maintained as long as the signal is on switch and relais 6057 758 101 2005 02 15 Description 2 Description 21 General configuration The ZF electronic control unit ERM can control ZF hysteresis clutches and brakes in different operating modes as required by the application The ERM is controlled by a microprocessor and features programming operation and diagnosis interfaces The ERM is designed for optimum supply of the ZF hysteresis clutches EKU and the ZF hysteresis brakes EBU Controlled operating modes with size coding are less suitable for performance optimized brake range The DIL switches enable the following operating modes t
21. tiometer setting e Nom voltage Upsnominal is calculated Da Q Q Up nominal AU ar AU Up Up Di Up gnominal nominal voltage outer diameter Da outer diameter Di inner diameter Up voltage outer diameter Up voltage inner diameter Q diameter ratio AU voltage difference Set UDa nominal by potentiometer 6057 758 101 2005 02 29 Operating modes 8 Set max roller 9 Push set key 10 Release set key Reference is accepted contr lights up 11 The installation is ready for operation NOTE Should the installation not function properly consult 4 Identification and causes of failure corrective action see page 38 3 Operating modes Electronic control unit ERM 3 4 Operating mode controlled with calculation 3 4 1 Function diagram ZF Hysteresis brake tensile force FW control unit TF Electronic aa ntl WN Curre 015237 Nominal traction 6057 758 101 2005 02 30 Ty Calc value 017181 Electronic control unit ERM Operating modes 3 4 2 Pin assignment Designation PIN connection Voltage supply plus 24 36 V 17 18 Voltage supply ground 1 2 ominal traction sensor 7 5 grinder 9 Friction factor 7 5 grinder 8 Roller speed fn 12 Feed rate fv 13 Set key 11 17 18 24 to 36 V Hysteresis brake 16 6 Hyster
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