Coiltek CS-5000 V2 Manuale utente

OPERATING MANUAL

CS-5000 V2

6676 Millersburg Road

Wooster, OH 44691

Tel: 800-883-7542 330-601-1350 Fax: 330-601-1352

Website: www.coiltek.com

 
 Contents 
 
Introduction............................................................................................................................................... 1 
Standard Configuration and Options......................................................................................................... 2 
Notes on Slack Loop Control.................................................................................................................... 3 
Notes on Slack Loop Control.................................................................................................................... 4 
Manual Set-Up.......................................................................................................................................... 5 
Extending Upper Limit ............................................................................................................................. 7 
Offset......................................................................................................................................................... 8 
Remote Access to Presets.......................................................................................................................... 9 
Terminals and Inputs............................................................................................................................... 10 
DIP Switch Functions ..............................................................................................................................11 
STOP Input.............................................................................................................................................. 13 
Cable Connections .................................................................................................................................. 14 
Software and Sensitivity ......................................................................................................................... 16 
Upgrading to the CB-5501M .................................................................................................................. 17 
Notes ....................................................................................................................................................... 18

Introduction

The CS-5000 is an ultrasonic sensor integrated with a microprocessor based control card. It has been

specifically designed to monitor strip, hose, paper, gasket material, tubing, coil stock, etc. hung in a

slack loop. Slack loop control is used for the feed and/or rewind of products manufactured in a

continuous, linear manner. The diagram below is more instructive of the CS-5000's purpose.

Typically, the CS-5000's sensor is placed over a draped loop of slack material. The position of the loop

valley is sensed and is used to govern the speed of a follower device (in the diagram, it's a powered

winder). The CS-5000 may be programmed to control either upstream or downstream process

followers. Typical of upstream devices would be decoilers, straightener/flatteners, dereelers. Typical

downstream devices would be winders, cut-to length machinery.

The ultrasonic transduction is fairly straightforward. A burst of acoustic energy is broadcast toward the

target (the loop valley). Milliseconds later, the transducer is switched to receive mode to await the

echo return. The time between transmit and receive is measured. The speed of sound in air is

reasonably constant so the position of the target is accurately calculated by the system's processor.

The system works best when the target viewed is perpendicular to the beam axis. Some angular

variation is tolerated (about +/- 5 angular degrees), but when the angle is too severe, the echo return

misses the receiver entirely. In this case, the system will register a far loop even if the target is

physically in the control range. Most loops have either a parabolic or catenary curvature which aids in

bouncing the echo back to the receiver, much like a radar dish does.

When the system is set-up, a control range is defined. Near and far set points define it. Within the

control range, a signal (both 0-10VDC and 4-20mA are available) varies from either low to high or

high to low.

Standard Configuration and Options

The CS-5000 V2 is, as the name suggests, a revision of a product Coiltek has made since 1994. The

latest version of the control (main) circuit board operates on 24VDC. This is a common industrial

standard voltage source. Since our older cards operated on either 115 or 230 VAC, our standard

configuration of the main board includes a small, 0.8W power supply, as shown below. The supply

accepts any AC power source between 90 and 240VAC. The supply requires only L1 and L2. Connect

incoming ground to the subpanel or enclosure.

The CS-5000 may be ordered without the supply (-LPS) when a 24VDC source of sufficient amperage

is available.

There are two vertical post sizes: 54”(~1.4M) and 72”(~1.8M). From the post, a boom or arm extends

out horizontally with the sensor. This way, the sensor is located over the slack loop. There are 9 arm

lengths available: 11”(290mm), 15”(380mm), 21”(533mm), 25”(635mm), 30”(762mm), 36”(91

cm), 39”(99 cm), 45”(114 cm) and 48”(1220 cm). Systems are specified as follows:

CS-5000-xxyy

Where xx= post height, yy = arm length.

The CS-5000 may also be ordered with an M12 connector termination.

Notes on Slack Loop Control

Loop Geometry

While it may seem counter-intuitive, slack loop control works best when the two points from which the

stock is draped are as close together as possible. It is the amount of slack or free material in the loop

that provides the time for the follower device to accelerate or decelerate.

In the diagrams above, it's clear that the deeper 'U' shaped loop develops the most free material

between long and tight loop, avoiding the generally undesired tight loop shown at the top.

There is a caveat: some materials will be damaged if pressed into too tight of a bend. The cross-section

of tubing or hose may be distorted or crimped. Thick metal strip may be pushed past elastic limits.

Good loop geometry is a balance between mutually exclusive parameters.

Notes on Slack Loop Control

Uneven Drape Points

When the slack loop is draped from uneven positions as shown above, the loop valley will shift. It will

always shift toward the lower drape point as the valley rises, regardless of stock flow direction. Note

the valley center lines with a full loop and tighter loop and position the sensor between the two. The

goal is to get solid position signal through the working span desired.

A similar situation occurs when using the loop control between a process and an un-winder or winder.

The depletion or growth changes the tangential wrap point –also the drape point –as the line runs.

Hence, the valley of the loop will move over time.

Speed of Response

Most slack loop control applications govern variable-speed powered follower machinery. When this is

the case, a well-proportioned loop will yield better performance if the control range is larger. A

reasonable amount of vertical travel between far loop set point and near loop set point will nearly

always improve follower performance as the slack material buys time for the powered follower to

respond.

Since the loop control measures position but is used to coordinate velocity, it is by definition integral

control. The characteristics of integral control are zero long term error with modest speed of response.

Hence, the CS-5000 on its own works well for slow to moderate speed processes. For higher speed

applications, it must be used in conjunction with more sophisticated control systems that will improve

speed of response.

Manual Set-Up

The CS-5000 is very easy to set up if the W1 jumper is in place. Here's how:

1. Press button S1. Lights above

buttons S2 and S3 will begin

to blink.

2. Put a target beneath the sensor

(unless the product is very

narrow, say <3/4” wide, use

the material you're running).

Place it in the position farthest

from the sensor. It will be the

outer limit of your control

range. Press S3. The light

above S3 will stay on and stop

blinking.

3. Place the same target at the

desired near point of the

control range. Press S2. If the

set-up is accepted, the lights

above S2 and S3 will go out

and the system will return to

run mode. Calibration is

complete.

Alternately:

1. Press button S1. Lights above buttons S2 and S3 will begin to blink.

2. Put a target beneath the sensor. Place it in the desired near position. It will be the upper

limit of your control range. Press S2. The light above S2 will stay on and stop blinking.

3. Place the same target at the desired far point of the control range. Press S3. If the set-up is

accepted, the lights above S2 and S3 will go out and the system will return to run mode.

Calibration is complete.

As shipped, after performing the procedure above, signal output will be 0VDC (4mA) at the far point

and 10VDC (20mA) at the near point of the control range. This output may be used to control

upstream or process feeding devices. In order to control downstream processes, the signal must be

inverted. To do this, turn on DIP switch #7.

Relays, Extended Upper Limit

When the set-up is complete, the near and far relays toggle at the respective near and far set points.

The relays operate in a fail-safe manner. Specifically, the NEAR relay is ON unless the near limit is

encroached. The FAR relay is ON unless the target drops below the far limit.

In feed applications, it is sometimes useful to move the near relay's activation point above the top of

the control range. The near relay is used to stop the leader process when the feed device isn't keeping

up. If the full 10VDC or 20mA signal is required to synchronize the feeder with the process, nuisance

trips transpire. Set up of this feature is described below.

Auxiliary Relays

The CS-5000 has two auxiliary relays that may be programmed to fire anywhere in the set control

range. To set them up,

•Turn ON DIP switch #8.

•Press S1.

•Lights above S2 and S3 blink.

•To set leftmost aux. relay, set target and press S3.

•To set the other aux. relay, press S2.

•Turn OFF DIP switch 8.

This set-up does not affect the basic loop control settings, however, relay operation is NOT fail safe.

These relays remain OFF until the target has reached or is nearer to the sensor than the set point.

Program Lock Out

As previously mentioned, the W1 jumper must be in place to manually program the system. When it is

removed, programming the system manually is not possible. This may be useful in plants where only

authorized personal are allowed access to machinery set-up.

Extending Upper Limit

Another important feature on all new boards shipped after 7/15/14 is the ability to set an extended

upper limit for the relay. This feature allows the user to set the emergency stop function higher than the

original high point of the loop, thus increasing the amount of top-loop max feed time and minimizing

nuisance stoppage. To use this feature, press the S2 and S3 buttons simultaneously. This causes the

unit to enter a near relay setup mode, indicated by LEDs above S2 and S3 turning on. Place an object

at the new near point you would like to set, and press S2 and S3 together a second time. The LEDs

above the buttons should go out. To cancel the near relay set-up, press the S1 button, returning the unit

to normal parameters. Ensure that the lockout jumper (W1) is in place before you attempt to use this

feature.

Offset

Offset bias is available and useful in some

situations. The graph at right explains what happens

when offset is employed. The standard control

signal is shown in blue in the foreground. Behind it,

the red shows the output of the CS-5000 when 25%

offset is implemented. Here, the output of the

control jumps to 2.5 VDC when the loop crosses the

long loop limit into the control range. The

discontinuity in the output may be useful when the

follower machinery must start rapidly. Since the

working slope is reduced, this feature is frequently

chosen in stamping operations with long feed

progressions. Feed 'wow' is reduced.

To set up offset, set DIP switches 1-3 in position to

implement the desired amount of offset. See the key

below. Using CSWin, offset as large as 50% may be

set.

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