Maschinen-Kontroll-Systeme GmbH

Zwischen den Wegen 32

D-78239 Rielasingen 2 - Germany
Tel. +49 (0)7731-9332-0
Fax +49 (0)7731-9332-30
E-Mail info@mks-control.de
Internet http://www.mks-control.de

CT 150
Precision Controller for Rotating Cutters and
Printing Rolls

• Stand alone unit for full closed loop control of the cutter drive

• Fully synchronous motion while cut or print is in progress

• Variable cutting length or printing pitch by S-shape speed profile of the roll

• Index and print mark control included

• Easy setup and commissioning by Windows operator software

• Excellent accuracy and dynamics by only 150 µsec of response time

• Parallel and serial and CANopen interface for auxiliary PLC and PC control

• Includes batch counters, line speed control and more facilities

CT15013N.doc / October 03 / 36 pages

Table of Contents: Page

1. Introduction 3

2. Principle of Operation 3

3. Configuration of a Cutting System 4

4. Terminal Location and Grounding/Screening rules 5

4.1 Encoders 7
4.2 Analogue connections 10
4.3 Power supply 10
4.4 Parallel Interface 11

5. Control IN/OUT Port 12

6. The Serial Port 15

7. Register settings 16

8. The Data IN Menu 16

9. Auxiliary Register and Command Codes 22

10. How to operate the Keypad 23

11. The LED Display 25

12. Remarks about Drives, Encoders, Cables, Installation 25

13. Steps for commissioning 26

14. Hints to improve performance 30

15. Physical Range of Cutting Lengths 31

15.1 Shortest length possible 32
15.2 Longest length possible 32
15.3 Dynamic requirements for the roll drive 32

16. General Master Reset and Erase of the EEprom 33

17. The BY 106-5 Remote Thumbwheel Switch 34

18. Dimensions and Specifications 35

19. History 36

These instructions have been written and checked to the best of our
knowledge and belief.
However, MKS will not be liable for errors and reserves the right for
changes at any time without notice.

2
1. Introduction

The CT 150 cutting controller is technically based on the BY 150 high performance synchro
controls. The software however has been especially designed for rotating cutter systems and
printing applications, with consideration of maximum cutting efficiency and accuracy at most
careful treatment of all mechanical parts.

All parameters are set fully digital and no potentiometers must be adjusted. The unit provides a
small keypad with LCD display for register settings. Also a windows operator software is
included on disc, featuring easy setup by a PC / Laptop / Notebook computer. Some of the most
important registers are accessible via parallel interface, allowing to preset cutting length and
other variables by a simple BCD thumbwheel switch or a PLC parallel output. All internal
registers are accessible by serial RS232 or 485 or CANopen communication.

The mechanical construction provides a fully closed 19“ steel cassette with all connections on
the front, guaranteeing excellent attributes with EMC immunity and emission. The cassette can
be mounted into any standard rack. With use of option SM 150, also easy mounting on DIN rails
is possible.

In some sections, this description uses expressions like „C02“, „C03“ which represent the serial
access code to the corresponding registers.

The unit is suitable for control of cutting applications as well as for partial printing
screens. This manual always says „cutting“ or „cut“ and the reader may replace this by
„printing“ when applicable.

CT150 CT150 CT150

20 RS232
PI 12345 RS485
BCD thumbwheel or CAN
Switch or PLC
TX720 Operator
terminal
PC
Examples how to operate the CT150 controller

Fig.1

2. 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 roll ( at
constant rotational speed ). Change of the cutting length needs exchange of the roll against
another one with appropriate diameter.
The CT 150 controller uses 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 by the processor in order
to get the desired cutting length. The CT 150 calculates the speed profile of the „asynchronous
zone“ 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.
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. Fig 1 shows two typical speed profiles.

3
 V V Cut
Cut Sync
Zone
Line Line
Sync
Zone

t t
Length > Circumference Length < Circumference
Fig.2

Continuous closed loop control of the relative roll position with respect to the length progress of
the line, combined with an update time as short as 150 µsec, 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 CT 150
must be able to accelerate and decelerate the roll under real closed loop conditions. However,
no special requirements are necessary for the line drive, and also a simple measuring wheel on
the material line is good for full performance.

3. Configuration of a Cutting System

In general, the Master drive will be the drive of a feed roll. With many applications, and with
special regard to possible slip, a measuring wheel with encoder can be better.

CT 150 version 10 A or later can operate with or without analogue feed forward signal. In
general, for new applications, fully digital operation will be chosen (line speed taken from the
master encoder only). But in order to be fully compatible to all former versions, the unit can also
operate with an analogue input proportional to the line speed. Analogue feed forward signal
must be used, when for reasons of poor master encoder resolution the master frequency does
not reach at least 1 kHz with maximum line speed.
The CT 150 controller uses encoders with RS 422- TTL line driver outputs ( 5V, A, A, B, B ) .
Where you must apply HTL encoders ( 10 - 30 V , A and B output ), it is necessary to use our
level converter PU 202 which converts your HTL signals to the proper RS 422 standard. Upon
special ordering information, the unit can also be modified for HTL encoder inputs.

Both, line encoder and roll encoder, should have at least 5 times the resolution of the maximum
cutting error you can accept. Please note you can set the unit to multiple- edge- counting
( section 4.1 ) which can reduce the real number of ppr correspondingly. At any time you must
be aware that the CT 150 controller accepts cutting errors of + / - 5 encoder increments or edge
counts, whatever this may be in terms of length tolerance. Please observe the maximum
encoder frequency which is 300 kHz.
The unit must receive a „cutting pulse“ with each revolution of the cutting roll. The rising edge of
this cutting pulse must be physically located somewhere in the synchronous zone ( i. e. around
the position where the tool performs the cut ). With respect to this rising edge, the user can set
a „prior to cut“ and an „ after cut“ zone where the tool must be synchronous to the line.

If applicable, a print mark sensor can be connected for fully automatic adjust of the cut with
respect to a printmark. Two Trim inputs provide manual displacement of the cutting point on the
material and also allow to jog the roll with the line in standstill. Fig. 2 shows the general block
diagram of the CT150 controller.

4
 Roll Encoder Cutter drive
Measuring wheel

Line
Encoder
+/-10V (or +10V)

Master Input Slave Input Analogue Output

A, A, B, B A, A, B, B
Power
24VDC
Ready
CT150 Reserve
RS232
Line out
Bold printed connections Markwindow open
Communication
RS485 are "must" Alert -
Ports
Other connections Outputs
are "can" Cut too short
CAN Cut too long
Alert +

Control Inputs Parallel Data Input

Reset
Trim +
Trim -
Read PI PLC or
BCD switch
Activate
Prog 1/2
Store EEprom
Start/Stop
Reserve
Reset Mark
Cutting pulse
Print mark
Fig.3
4. Terminal Location and Grounding/Screening rules

5
For reasons of proper screening, it is a must to follow the subsequent instructions.

Where you don’t exactly observe these grounding and screening rules, it is almost for
sure that you will have problems later!

a. The minus wire of the power supply must be connected to the grounding screw on the front
plate of the CT150 controller with a short wire of at least 0.75 mm².

On site of the power supply, the minus output must be earthed.

Where the wires between power unit and CT150 controller are longer than e.g. 1 meter, it is
advisable to ground the front plate of the controller again by a separate wire, on the shortest
way possible.

CT150
+24V

Power Supply
PE Supplement short earthing when power cable is long
Fig.5

b. All screens on the controller side must be connected to the housing of the corresponding
Sub-D-connector. This is valid for encoder cables, analogue output and PI or PO lines.
Where you use Sub-D-connectors with a plastic housing, you must solder the screen to the
metallic frame of the connector. At any time you must be sure the screen gets a proper
contact to the front facia of the unit when connected to the controller.

Screen
Fig.6

c. When encoder cables are interrupted by terminal boxes or intermediate connectors on their
way from the controller to the encoder, you must connect the screen to the Minus wire of the
encoder supply there, but never to earth potential again!!.

Encoder cable
to encoder to CT150

Minus of encoder supply

Screen

Tie Minus of encoder supply and screen together whereever

you interrupt the encoder cable by terminal or connectors.
Make sure the screen can never get any earth potential here!
Fig.7

6
 d. When the cable arrives at the encoder site, the screen must again be connected to the
Minus wire of the encoder supply, but not at all grounded to earth. In general, there are two
types of encoder connections:

Encoder with plug connector

Shaft
Encoder Make sure the screen of the cable is connected
to the Minus supply of the encoder, but does not
touch the metallic housing of the connector.

Fig.8

Encoder with cable end

Shaft
Encoder From CT150

Leave this screen fully unconnected

here to avoid illegal double earthing! Connect screen to the Minus wire of the
(Screen is internally earthed to encoder supply here. Avoid any earth
the encoder housing.) connection via contact to housings etc.
Fig.9

e. With all other cables like analogue output, control or parallel output, put the screen to the
metal connector housing on the CT150 side and leave it unconnected on its peripheral side.
Again avoid double earthing. The only place where the screen is earthed must be the front
plate of the unit!

Example : Analogue speed reference signal

Drive

Speed
Ref. to CT150

This screen unconnected

and not earthed! This screen to metal frame of Sub-D-Connector
Fig.10

4.1 Encoders

The unit only accepts TTL impulse signals ( 5V, RS 422 ) or similar from an encoder simulation
(resolver). It is essential to connect the channels A, A, B, B:

The index inputs Z and Z of the slave can be used to generate the cutting pulse, but this
needs the slave encoder to be directly mounted to the cutting roll, because only one cutting
pulse per cut can be accepted. Also, in this case the encoder must mechanically be mounted in
a way that the index pulse appears inside the synchronous cutting zone.
Under regular conditions it makes no sense to use the index inputs Z / Z of the master
channel. It is register selectable if you use the corresponding HTL inputs at the control in / out
port with a photocell or proximity switch, or the TTL inputs with the encoder index. See register
“Index Mode”

7
Where you find you are working with existing 10 - 30 Volt encoder signals which feature only
A / B / Z signals, the PU 202 converter should be used to gain full complementary signals in line
with RS 422 standards.

An auxiliary voltage of 5,0 V ( max. 400 mA ) is available on the connector plugs “Master“ and
“Slave“, for easy supply of the encoders. This voltage uses the same GND as the power
supply, the digital inputs and the analogue output. Both encoder connectors on the unit are Sub
- D - 9 pin, male.

Fig. 4 and Fig. 5 show the encoder connections and the principle of the input circuit. All impulse
inputs are driven by high speed optocouplers.

When connecting the encoders it is not important to wire the A and B signals to produce the
correct counting direction. The direction can be determined in the setup menu.

+5V Vcc int.

DC

0V DC GND int.
B A A B A A

1 2 3 4 5 1 2 3 4 5
6 7 8 9 6 7 8 9 GND

DIL-Switches 1-4 have no function.

Z Z B Z Z B (different from previous hardware versions)
Master Slave
Fig.11

Input circuit (principle)

4
A
220

Opto + 5VDC
VCC int.
DC
A
220 - 0V DC GND int.
Opto

5 GND
Input currents approx. 10mA
Fig.12

Important

• With encoders, supplied by the CT 150:

Connector pins 4 and 5 provide the encoder supply.
• With encoders, supplied by an external source, or when an encoder simulation
from the drive is used (Common GND operation)
Use connector pin 5 as common zero Volt potential.
• For fully potential-free operation:
Connect only A, A and B, B and leave terminal 5 ( Common ) unconnected.
For reason of best noise immunity, we recommend to use potential- free operation
wherever you have line driver signals with remote supply.

8
Warnings:

• Pin 4 of the Master and Slave encoder connectors is a supply output and you must
never apply external voltage to this pin. Serious damage of the controller would be
the result!

• Where you use one common encoder for feedback of the drive and feedback for the
CT150 at the same time, there may come up interference problems. You can use a GV150
impulse splitter to eliminate any kind of problems. In most applications, the common
encoder would also work fine when it is supplied by the drive and the CT150 operates in
fully differential mode like shown.

+
Encoder A
A Drive
B
B

Screen

4 (NC)
9
1 CT150
Do not connect pin 4 or 5 with fully 2
differential operation! 3
5 (NC)
Fig.13

DIL switches S1 / 5 - 8 provide the selection of the encoder edge counting. It is possible with
complementary signals to count with times 1, 2, or 4 without any fear of miscounting. The
selection always applies separately to the master and the slave input signals.

Master:
DIL-Pos. 5 DIL-Pos. 6 edge count
ON ON x1
OFF ON x2
ON OFF x4
OFF OFF counter disabled

Slave:
DIL-Pos. 7 DIL-Pos. 8 edge count
ON ON x1
OFF ON x2
ON OFF x4
OFF OFF counter disabled

9
 Please note, that

• the maximum frequency of the CT 150 refers to the total number of edges counted, i.e.
300 kHz ( x1 ) or 150 kHz ( x2 ) or 75 kHz ( x4 ).
• impulse numbers, to be entered upon setup, also refer to the total number of edges
counted, i. e. the entry data must be doubled with ( x2 ) etc.
• When possible, you should set the switches in a way to produce approximately similar
impulse numbers on Master and Slave side to achieve best operation. i.e. 4096 impulses x
1 on the Masterside and 1000 impulses x 4 on the Slave side.

4.2 Analogue Connections

All the analogue input and output signals can be found on the 9-Pin Sub-D connector (female)
marked as "Analog" on the front plate. The Analogue common GND is internally connected
to the minus of the 24 VDC supply. All analogue levels are in range +/- 10 Volts.

When you use the digital feed- forward mode, you must only connect pin 7 which is the
analogue output for the cutter drive speed reference.

When you use the analogue feed- forward mode, you must apply a 0 - 10 V analogue signal
proportional to the line speed to pin 6.

Pin 4, 5, 8 and 9 are for special purpose and must normally remain unconnected.

Summ .in
- + (internally connected)

5 4 3 2 1
GND
9 8 7 6

Out2 LVin
Korr LVout
Analogue Connector
Fig 14

4.3 Power Supply

The CT 150 operates from an unstabilised 24 VDC supply (+/- 25%), however, the voltage
including ripple should not exceed the following limits (18 V...30 V). The supply of the CT 150 is
both electrically and mechanically protected against wrong polarity misconnection by protection
diodes and a special plug.

Warning:
At pin 1 of the "PI" connector and pin 1 of the "PI/PO" connector, a +24V output is available for
easier wiring of input and output supplies. This voltage is taken from behind of a current limiting
resistor. Short circuiting these outputs to GND can burn the resistor or internal printed lines.
aux. out
Pin 1 of PI/PO connector
aux. out
Pin 1 of PI- connector
R
+24V
2 Ohms/ +
1Watt 470 uF Internal
GND
Fig.15

10
4.4 Parallel Interface

The interface provides remote setting of operational and configuration registers. It receives BCD
or binary data (selectable) from a remote thumbwheel switch or PLC control. There are four
binary coded select lines which provide up to 16 addresses being accessible, via 20 data lines.
The register parameters are stored in the following manner:

a. Store the parallel data upon a Read pulse. The data is then latched into the internal buffer,
without affecting the control operation at this point.

b. Activate data upon an input pulse. All the data stored in the buffer is loaded and executed.

It is easy to see how 16 external registers may be easily loaded into the CT150.

The connection of the parallel interface is a 25 pin Sub-D connector (male) which is marked as
"PI" on the front facia.

All inputs are fully PLC compatible. All signals refer to GND and the minus potential of
the supply.

Logic 0 ( low ) = 0.....8 Volts

Logic 1 ( high ) = 18...30 Volts

Important Advice

Upon power up, the unit loads the full register set stored in its EEProm. Data transmitted from
the parallel and/or serial interface will overwrite the operational RAM-data, but not the corres-
ponding EEProm registers. As a result, when powering up, any parallel or serial data will be
replaced by EEProm data, until it is overwritten again.

The RAM data however can be restored to the EEProm at any time by parallel or serial
command.

Parallel interface operations must keep the following timing conditions:

Data valid BCD DATA

Read impulse
T1 min. = 5 msec.
T1 T2
T2 min. = 5 msec.
Fig.16

Data latch occurs with the positive transition of the strobe pulse. Data lines must be in a valid
state at least 5 msec prior to the strobe, and remain present for an additional 5 msec while the
data is read. There is no upper limit for T1 and T2.

11
 1 + 24V out
S4 S3 S2 S1
14 S1 0 0 0 Length (C05)
Select 0
2 S2 0 0 0 Pho - Offs. (C12)
Lines 1
15 S3 0 0 1 0 Pho - Cut (C11)
3 S4 0 0 1 1 P1 Cut (C08)
16 BCD1 P2
Low order 0 1 0 0 Cut (C07)
4 BCD2 1 1 Circ 1 (C00)
digit 0 0
17 BCD4
(LSD) 0 1 1 0 Circ 2 (C02)
5 BCD8 0 1 1 Trimm (C04)
1
18 BCD1 1 0 0 0 Cut/Rev (C09)
6 BCD2 1 0 1 Mark/Len (C10)
MSD -3 0
19 BCD4 1 0 0 Mode (C40)
1
7 BCD8 1 0 1 Ramptime (C17)
1
20 BCD1 1 1 0 0 Gain - Cor (C46)
8 BCD2
MSD -2 1 1 0 1 Gain-Tot (C48)
21 BCD4 1 1 1 0 ppr1 (C01)
9 BCD8 1 1 1 1 ppr2 (C03)
22 BCD1
10 BCD2
MSD -1
23 BCD4 With signed parameters the most
11 BCD8 significant bit (pin 13) is used as
24 BCD1 sign bit (low = +).
High order
12 BCD2
digit When using binary format pin 16
25 BCD4
(MSD) is the LSB and pin 13 is the MSB.
13 BCD8
Fig. 17

5. Control IN/OUT Port

There are 12 control input lines and 8 control output lines available on the 25 Pin Sub -D -
Connector (female). This is marked on the facia PI/PO. All the inputs are the same as the
parallel inputs. All the outputs are opto-isolated transistor outputs which are PLC compatible.

13 Reset
25 Trim +
12 Trim -
24 Read PI data
11 Activate PI data
23 Prog 1/ Prog 2
10 Store RAM to EEprom
22 Start / Stop Inputs
9 Reserved
21 Reset mark counter
8 Cutting pulse 15 K
20 Printmark pulse 2,7 K
7 GND
19 GND
6 Opto Com+
COM+
18 COM+ 10-30V
5 Ready 33 R
17 Out
Reserved
4 Pulse/Length
max. 75 mA
16 Markwindow open
3 Alert- Outputs
15 Cut too short
2 Cut too long
14 Alert +
1 +24V out
Fig. 18

12
Reset ( 13 ) :
A High signal switches off the digital closed loop control and the unit only operates in an
analogue open loop. When a Reset signal is applied with the Start / Stop input in High state, the
unit also executes a new initial software startup cycle.

Trim - ( 25 ) Trim + ( 12 ) :
Shifts the cutting position forward or reverse, i. e. the unit temporarily cuts longer or shorter
pieces while one of the Trim inputs is High. With print mark registration, the Trim inputs can be
used to adjust the cutting position with respect to the mark. Once it has been placed correctly, a
„Store to EEprom“ command will store the cutting position and the unit will find the correct
position automatically again after power down. Trim inputs can also be used to jog the roll while
the line stands still.

Read PI data ( 24 )* :
Reads values of BCD or Binary code on parallel input. These values are stored in 16 separate
buffer memories, as selected. This data is not activated until the following input is made.

Activate PI data ( 11 )* :
A rising edge of this input tranfers the data from the buffer memory to the operating memory.
* ) N.B It is permissible to activate both „Read“ and „Activate“ inputs at the same time.
Thus for instance, a common input can be used to enter a new cutting length.
(Jumper pin 24 and pin 11)

Prog1/Prog2 (23):
The unit can store two completely different sets of parameters and, depending of the
production, use either parameter set 1 (Pin 23 low) or parameter set 2 (pin 23 high).

Signal changes on this input will only become active when

• either power is switched off and on again
• or the start/stop input goes high and the cutting roll comes to standstill

Store RAM to EEprom ( 10 ) :

A rising edge at this input stores all actual operational data to the EEprom and the same data
set will be loaded again after power down. It is recommended to use this command only at
standstill or low speed, beause it could affect the accuracy of the subsequent cut.

Start / Stop ( 22 ) :
With Low state, the unit operates in a normal cutting cycle. When the input goes High, the
subsequent cut is still executed normally and then the cutting roll decelerates to a closed loop
stop position, following the ramp set to the Ramptime register.

Reset mark counter (21):

When using print mark operation, many times we find several marks on one size of the sheet
to be cut, and only one of these marks is valid for registration. The unit can automatically
blank out the other marks by defining the active mark as follows:
Set this input to high when the valid print mark is close to the print mark sensor, but is not yet
sensed. Move the line slowly until the sensor detects the mark and switches from low to high
(rising edge required!). The Reset mark counter input must go back to low state before the
sensor generates the next rising edge from the following mark. This stores the position of the
valid print mark and the unit will not trigger to the other marks between. See also register
Mark/Window.

Cutting Pulse ( 8 ) :
This input must receive one impulse per revolution of the cutting roll (unless the TTL index
pulse of the slave encoder is used) and the rising edge of the impulse must be somewhere in
the cutting zone, since it serves as reference for definition of the synchronous phase. When you
have several tools on the roll ( i. e. for several cuts per revolution ), refer to register „Cuts / rev“.

13
Print mark pulse ( 20 ) :
Connect the print mark sensor to this input if applicable. Otherwise leave it unconnected. Print
mark registration refers again to the rising edge. The mechanical distance between mark sensor
and cutter is register settable.

Hint for print mark registration:

With missing marks or those which were not detected correctly, the CT 150 automatically
places the cut to the position where the mark should have been. However, a sudden change of
print mark distance which is not in multiples of the normal distance will result in a new searching
process and the outputs „Cut out of tolerance“ will switch on until the mark position has been
reached again.

Control Outputs

Ready (5):
This announces that the unit is ready to run. On power up, this output is "Low" for about three
seconds to allow the power supply to settle, and then switches to "High".

Warning: When "High", the unit could not detect a system fault itself, but this is not a
guarantee for fault-free operation!

Pulse/Length (4):
This output generates impulses proportional to the line motion, with scalable length units and a
1:1 duty cycle. As an example, the output can be used to count the total length in „meters“ by
use of a remote counter or a PLC.

Mark window open (16):

This output goes high while the mark window is open. You have specified the position of the
rising edge of a valid mark by the function „Reset mark counter“. You will also specify a
window around the position where the valid mark must be expected, by the "Mark
window" register. The output says that this window is open now and the next rising edge
of the mark detector will trigger the print mark control.

Alert - ( 3 ) Alert + ( 14 ) :
These outputs signalise that the cutting roll is not in the exact angular position where it should
be with respect to the line. Mechanical problems or drive overload could be the reason.

Cut too short ( 15 ) Cut too long ( 2 ) :

These outputs signalise that one or several cuts are out of the tolerance window set by register.
Sudden change of print mark distance or insufficient drive response could be the reason.

14
6. The Serial Port

The RS 232 serial link can be used for two purposes:

The unit includes a serial RS232 and a RS485 interface, both accessible by the Sub-D-9
connector marked „RS232“.
RS 232

TxD
NC RxD

GND Serial interface

int. 5 4 3 2 1 connector
9 8 7 6

+5V T+ T- R+ R-

RS 485
Fig.19

To run the OS 3.0 operator software with your PC by RS232, your PC must be connected to the
CT150 unit like shown:

RxD RxD
2 2
TxD TxD
PC 3 3 CT150
GND
5 5

Sub-D-9- female Sub-D-9- male

Only pins 2, 3 and 5 must be wired and pins 2 and 3 must be crossed
Fig.20

Please make sure your PC serial cable uses only the three pins shown. When also other pins
are connected, this will cause interference with the RS485 pins and the PC communication will
not work.

When using the RS485 interface, you can serve up to 32 different bus participants in either 2-
wire or 4-wire transmissions mode. the subsequent figures show, as an example, how to run a
TX720 operator terminal with a CT150 unit and other controllers.

Shield

2x 2x
120 Ohms 120 Ohms

T+ T- R+ R- R+ R- T+ T-

8 7 6 1 6 1 8 7 R+ R- T+ T-
TX720 CT150 Other device

RS485 (4-wire system)

Fig.21

15
 T+ Shield

120 Ohms T- 120 Ohms

8 7 8 7

TX720 CT150 other device

RS485 (2-wire system)
Fig.22

A detailed description of the serial protocol is available upon request or can be downloaded
from the Download site of the mks homepage (www.mks-control.com, document name: „Serpro“)

7. Register settings
Registers can be set by keypad under LCD control or by PC, using the OS30 operator software.
This section describes the registers and their meanings and the next section shows how to
program the registers.
The unit provides 4 Sub-Menus.
Data In Contains operational registers.
Setup Contains registers that need to be set only once upon commissioning.
Adjust provides easy setting of the analogue gains upon commissioning.
Test prog executes various testing functions for internal and external signals.

Expressions like C00 indicate the serial register access codes.

8. The Data IN – Menu

B A
Data In Set - up Adjust Testprog

C00 Circ 1 C40 Mode Gain - Cor Mast-Dir

C01 PPR 1 C41 LV-Cal Gain - Tot Slav-Dir
B C02 Circ 2 C42 PI-Form Offs-Cor B
C03 PPR 2 C43 Add-Cor Gain-Cor
C04 Trimm C90 Unit-Nr. Offs-Tot
C05 Length C91 Baud-Rat Gain-Tot
C06 Min. Len C92 Ser Form Led + PO
C07 Cut ->P2 C93 Bus-Add Cont. in
C08 P1 -> Cut C94 Bus-Baud PI in
P C A P C A
C09 Cut/Rev C95 Bus-Config Factory
C10 Mark/Leng C96 BusTxPar
C11 Photo ->Cut C97 BusRxPar
C12 Pho-Offs C45 Master-Dir
C13 Mark/Win C46 Slave-Dir
C14 Cut - Tol C47 Offs-Cor
C15 Alert C48 Gain-Cor
C16 Cor-Divi C49 Offs-Tot
C17 Ramptime C50 Gain-Tot
C18 Vmax/Vlin
C19 Ind. Mode
C20 +/- Sync Rate
C21 Length Cor
C22 Length/Pulse
C23 Pow Sens
C24 SampTime
C25 Ramp Form Fig. 23

16
Circ 1:
This register must be set to the circumference of the line feed roll or the measuring wheel. You
are free to set it in any dimensions (i. e. inch, millimeters or 0.1 millimeters), but herewith you
fix up all other length dimensions (for other registers, length preset, photocell distan-ce etc.) If
you enter Circ 1 with 0,1 mm resolution, all following presets will be scaled with 0,1 mm steps.
Range 1 - 65535

PPR 1:
Pulses per revolution of the feed roll. Enter the number of pulses from the master encoder for
one revolution of the roll, or measuring wheel.
Range 1 - 999 999. Observe count setting (x1, x2, x4).

Circ 2:
Circumference of the cutting roll. Range 1 - 65535 length units

PPR 2 :
Pulses per revolution of the cutting roll. Range 1 - 999 999

Trim:
Speed for positional displacement of the cutting position, when using the Trim inputs. Entry is in
software cycles ( 1 cycle = 100 µsec ) necessary to displace the cutting roll by one slave
encoder increment. With setting 001, the unit changes the position by 1 encoder increment
every 100 µsec. With setting 999 we need 999 x 100 µsec to change the position by one
increment.

Length:
This is a default length which the cutter will cut upon missing remote length preset. It will also
cut the default length whenever the slide switch is returned from PRG to its RUN position.
Range 1 - 999 999 length units.
We recommend to always set this register similar to the Circ 2 register (continuously
synchronous roll speed).

Min. Length:
Minimum cutting length. Limits the length setting range in order to avoid operator mistakes

Cut → P2 :
This register defines, how long after the rising edge of the cutting pulse the roll must remain
synchronous before the speed profile starts to change speed. Entry in length units.
Range 1 - 9999

P1 → Cut:
Similar to above, but distance prior to the rising edge of the cutting pulse. Range 1-9999

P1- Cut Cut - P2

Line speed
P1 Cut P2

Roll speed

Cutting pulse
Fig. 24

Cuts / Rev:
Set this register to 1 when your roll uses only one tool at it‘s circum-ference to perform one only
cut per revolution.
There are two ways of setting when you have mounted two or more tools around the roll and
one revolution performs two or more cuts.

17
a ) You have one only cutting pulse per revolution of the roll ( where i. e. two cuts are executed
). Then set this register to the number of cuts the roll performs with each revolution. The CT
150 then will generate the missing cutting pulses internally.

Example: Two cuts per revolution, but only

one cutting Pulse : Set Cut / rev. to "2"
Fig. 25

b) You use several cuts per revolution, but each cut will also generate a cutting pulse. Then
preceed like follows:
− Set register „Cut rev“ to 1
− Do not set the real circumference to the register „circ 2“, but set it only to the part of the
circumference between two cuts.
− Set also the ppr2 register to the number of pulses for one cut.

Example: Two cuts per revolution, but also two cutting

pulses per revolution : Set Cut / rev to "1".
Set "circ 2" to half of the real roll circumference.
Set "ppr2" to half of the ppr. Fig. 26

Marks / Length:
For print mark registration only:
Set this register to „1“, when you have only one print mark with each cut. Set it to the number of
print marks between two cuts, when you find several marks, but the cut should only be
executed with one specific mark.

Pho → Cut:
With print mark registration only.
Preset of the mechanical distance between photocell and cutting position.
Range 0 - 999 999 length units.

Pho → Offs.:
With print mark registration only.
Fine adjustment of the desired cutting position with respect to the print mark. Setting to „0“
results in placement of the cut to the edge of the print mark ( rising edge of the photocell ).
This register is also accessible remotely by parallel input. Range +/- 9999 length units.

Photocell Cutting roll

Photo-> Cut

+ -
0
Pho-Offs. Fig. 27

18
Mark Window:
With print mark registration only. Defines a symmetric window around the rising edge of the
print mark sensor. The print mark is supposed to appear inside this window and signals outside
the window will not trigger the print mark registration. See also input „Reset mark counter“.
Range 0-999 length units. You must set this register to 00 if not used.

Cut Tolerance:
Defines the switching level of the outputs „Cut too short“ and „Cut too long“. Range 0-99 length
units. Increments the waste counter and the cycle counter for automatic length overwrite (with
print mark mode) every time when exceeded.

Alert:
Defines the switching level of the alarm outputs when the system is forced out of
synchronisation due to external events ( drive fault or mechanical problem ). Setting occurs in
„error encoder increments“ and the alarm outputs switch on when the positional error of the roll
in respect to the scheduled position overpasses the number of encoder bits set. Range 1 -
9999.

Cor-Divi:
Correction divider. Setting range 1-9. This provides a digital attenuation of the phase correction
signal that is produced, when the drive on mechanical grounds (deadband or backlash) cannot
respond. In such a case, it is not desirable to make corrections immediately. The "Cor-Divi"
provides a window for the drive "backlash", within which the controller produces no correction.

Value 1 = No window, Reaction to 1 error increment.

Value 2 = Window +/- 1 Encoder increment.
Value 3 = Window +/- 2 Encoder increments.
Value 4 = Window +/- 4 Encoder increments.
Value 5 = Window +/- 8 Encoder increments. etc.

Ramp time:Ramp time to stop the cutter drive.

Range 0.01 - 9,99 sec. This ramp has absolutely nothing to do with the ramps the unit
uses in normal operation, because it automatically calculates the softest speed transition
possible. The ramp register only stops the drive when you slide the keypad enable switch from
„Run“ to „PRG“ while the drive is running, or when you use the Start/Stop input to stop the drive.

Vmax / Vline:
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“ can be recommended.

19
Ind Mode:
This register selects the index source ( i. e. the cutting pulse and the print mark pulse ). You are
free to use either the TTL inputs on the encoder connectors, or the HTL inputs at the control IN /
OUT port PI / PO.
Index Mode Cutting pulse Print mark
source source
HTL, pin 8 HTL, pin 20
0 on PI / PO on PI / PO

TTL index pins HTL, pin 20

1 6 and 7 at Slave input on PI / PO

HTL, pin 8 TTL index pins

2 on PI / PO 6 and 7 at Master input

TTL index pins TTL index pins

3 6 and 7 at Slave input 6 and 7 at Master input
Fig.28
+/- Sync Rate:
Percentual adaptation of the circumferential roll speed to the line speed during the synchronous
cutting phase. Setting range +/- 99,9%. When set to 00.0% (normal setting), the tool will be fully
synchronous with the line upon the cut. Some applications may require slightly higher or lower
speed due to the shape of the cutting tool, which can be set by this register.
Length Correction:
With print mark registration only. Automatic overwrite of the length setting by the print mark
distance found by measurement. Setting range 0 – 9
0 = overwrite switched off
1 = overwrite after 1 cycle
2 = overwrite after 2 cycles
3 = overwrite after 4 cycles
4 = overwrite after 8 cycles
Clarification: when cutting or printing paper or foils with print marks, the material can shrink or
stretch for reasons of tension, ambient temperature, humidity etc. As a result, the distance
between two print marks (i. e. also the cutting length) will change and no more exactly match
the preset length. Due to the proportional control feature of the CT150 unit, this would also
cause a slight displacement of the real cutting position with respect to the print mark.
The „Length Correction“ register sets a number of cutting cycles where the cut must be out of
tolerance (register Cut-Tolerance) in always the same direction and consecutively. When
reached, the length preset is automatically overwritten by the real length measured between the
print marks and proportional position errors are eliminated.
Length/Pulse:
Scaling factor for the auxiliary impulse output. Setting range 1 – 99 999 length units per
impulse. If the whole system is calibrated in „Millimeters“ and the output should be used to
count and totalise the line with integer meters, set this register to 1000 to receive one impluse
every meter
Power Sense:
0 = batch counters not stored in the EEprom upon power down
1 = batch counters stored in the Eeprom
Sampling Time:
Provides digital filtering of the feed forward signal generated from the line encoder.
Range 0001 - 1000 msec. Normal setting 1 msec recommended.
In applications where the line speed is very unsteady, settings like 10 or even 100 msec can be
advantageous for smoother motion of the rotating knife. Please note that higher setting results
in lower response with changes of the line speed.
Ramp Form:
1 = speed profile with S-shaped polynominal ramps (suitable best for nearby all servo drives)
2 = speed profile with straight linear ramps (sometimes preferable with big DC drives)

20
Mode:
Mode 1: Operation without print mark
Mode 2: Operation with print mark

Important hint:
When you use never print mark operation, set Mode to “1“.
When you use always print mark operation, set Mode to “2“.
Where you run mixed production (sometimes with and other times without print mark): Set
Mode to “2“ and install a select switch to apply or remove the print mark impulse to pin 20 of the
Control IN/OUT port, according to actual need.

LV - Cal:
Selects analogue or digital Feed Forward mode
LV - Cal = 1 : Analogue Feed Forward. Apply a 0 - 10 V signal proportional to line speed to pin
6 of the analogue connector.
LV - Cal = 2 : Digital Feed Forward. Leave pin 6 of the analogue connector open. Unit
generates Feed Forward signal from master encoder.
Use always setting „2“, except you need analogue feed forward for special reasons.

PI - Form:
Selects the inpu code of the parallel interface ( PI ):
0 = data entry with BCD code
1 = data entry with binary or hexadecimal code

Add - Cor:
Switches the internal summation of the analogue correction signal on / off.
0 = off, open loop mode with no correction
1 = on, closed loop mode with correction superimposed
Must always be set to “1“ with regular operation!

Unit-Nr:
For serial operation only. Allows entry of a device address between 11 and 99. It is not
allowed to use addresses containing a "0" ( i. e. 20, 30, 40 etc.) as these are reserved for
collective addressing of several units. Factory setting “11“.

Baud-Rate: For serial operation only. The following transmission rates can be selected:
0 9600 Baud
1 4800 Baud
2 2400 Baud
3 1200 Baud
4 600 Baud
5 19200 Baud
6 38400 Baud
Fig.29
Factory setting “0“
Ser-Form: For serial operation only. The following formats of serial data can be selected:
Ser-Form Databits Parity Stopbits
0 7 Even 1
1 7 Even 2
2 7 Odd 1
3 7 Odd 2
4 7 None 1
5 7 None 2
6 8 Even 1
7 8 Odd 2
8 8 None 1
9 8 None 2 Fig.30
Factory setting “0“

21
 Bus-Add, Bus-Baud, Bus-Config, BusTxPar, BusRxPar:
Only relevant for units with option “field bus interface” (CAN-Bus or PROFI-Bus DP). See
supplementary instructions for further information.

Mast Dir :
Direction of phase of the master encoder. Settings can be changed from „0“ to „1“ in order to
change the direction of internal counting. Changing this bit does the same as interchange of the
A / B encoder channels. For correct setting see „Steps for commissioning“.

Slave Dir:
Similar to above, but for slave encoder.

Off-Cor:
Digital setting of analogue offset on correction signal. Setting range +/- 99. Normal setting "0" *)

Gain-Cor:
Digital setting of gain control (proportional control)
Range 0 - 9999. Setting to 9999 results in a response of 100 mV per error bit. Recommended
setting: 200....2000 ( i. e. 2 mV....20 mV per error bit).

Offs-Tot:
Digital setting of the offset on the slave speed reference output.
Range +/- 99. Normal setting "0" *)

Gain-Tot:
Digital setting of the feed forward analogue output gain. Setting range 0 – 999999.

*) Remark: CT 150 uses precision instrumental amplifiers which do not need an offset
adjustment. In larger drive plants however, by balance currents between several devices, an
external offset can build up, which can be compensated by the offset adjust.

9. Auxiliary Register and Command Codes

The following auxiliary registers are accessible by serial link, with the access codes shown
(R = Read only, R/W = Read/write)

Code Name Function

:1 Error Count (R) Shows the differential number of encoder increments
between the scheduled roll position and the real roll
position at any time
:2 LV Value (R) Represents the actual feed forward signal (speed
profile) of the cutting roll drive.
0 = Standstill 4095 = maximum speed.
:6 Printmark Error (R) Difference between actual and desired position of the
cut with respect to the printmark. Unit: master
encoder increments. (Only available when Mode = 2)
:7 Batch Counter (R/W) Increments with every cut executed. Can be preset to
zero or datum.
:8 Waste Counter (R/W) Increments with every “Out of tolerance“ cut. Can be
preset to zero or datum.
:9 Line Speed (R) Represents the encoder frequency of the measuring
wheel. 1 bit = 5Hz.
<4 Actual Cutting Length (R) Actual length of the last cut.

22
 Beside the serial access codes shown in this manual, the subsequent codes are available to
execute the same commands that can be activated by the hardware inputs also:

Ser. Code Bit of control word (C86) Function Type

55 14 Reset mark counter S
56 4 Read PI data D
58 0 Start / Stop S
60 7 Reset S
65 6 Trim + S
66 5 Trim - S
67 3 Activate data D
68 1 Store EEPROM D
S = Static command, must be set to 1 to activate command and
must be reset to 0 to deactivate command.
D = Dynamic command, must be set to 1 to activate command.
Is automatically reset to 0 after execution.

All commands can be activated either by its serial access code or by setting the corresponding
bit of the control word (Ser. Access code 86).

Please note that all serial commands are logical ORed to hardware commands (control inputs)
and hence a command is ON whenever set by serial command or hardware input or both at a
time.

The state of the control outputs can be read out by the status word (Ser. Access code 85) via
serial interface. Bit 7, 6, 5, …, 1, 0 of the status word correspond to control outputs PI/PO pin 5,
17, 4, 16, 3, 15, 2, 14.

10. How to operate the Keypad (not needed with PC setup)

LCD-Display

Run Processor
A B C P PRG
PRG

S1 DIL

Fig.31

To access the operator PCB, remove right hand side plate.

The on board setting controls comprise an LCD display, 4 small buttons and a sliding switch.
When the switch is selected to "Run", the LCD permanently displays the software version of the
program and the buttons A, B, C and P have no function.

Programming by the on board setting controls requires the sliding switch to be slid to "PRG".
For external PC setting it must however be in the „Run“ position.

The buttons have the following control functions (Cursor highlights the register):

23
Button A: Scrolls register down; scrolls menu forward and also increments the highlighted
digit.

Button B: Scrolls registers up; scrolls menu backward and also decrements the highlighted
digit.

Button C. Returns from register to menu titles; increments highlighted digits to the right, (or
from full right to full left).

Button P: Enters from menu to registers; changes register from text to value and back to text
again. Stores actual data to the EEprom.

The following example shows how to set the “Trim“ register of the Data In menu (see register
table).

Action LCD

• Slide the switch to “PRG

Data IN

• Select the Data IN Menu by pressing “P“

Circ. 1

• Press “A“ several times until the LCD shows “Trim“

Trim

• Select the Trim register by P and read the actual setting

(i.e.100) 1 0 0

• Change setting to i.e. 500 msec like shown:

• Key B decrements digit highlighted by cursor

0 0 0

• Key C shifts cursor right

0 0 0

• Key A increments highlighted digit. Press A 5 times.

0 5 0

• Press P to store the new value

Length

When you slide the switch back to “RUN“, you read again “CT15010A“ and the unit is ready to
operate.

When you press “C“ instead, you come back to “DATA IN“ etc.

Please note: The unit is unable to operate or to make serial communication while the slide
switch is in the “PRG“ position!

24
11. The LED Display

The 8 LED`s mounted on front of the module indicate the instantaneous angular error between
the real roll position and the position where it should be with respect to the actual line position.
The display provides information for commissioning and fault monitoring, in a very simple but
efficient form.

red 256 +++

128 - 255 +
orange 64 - 127
32 - 63
yellow 16 - 31
8 - 15
green 1-7
+/-0
green 1-7
8 - 15
yellow 16 - 31
32 - 63
orange 64 - 127
128 - 255 -
red 256 +++
Fig.31

When both green LED`s in the centre are lit, the phase error is absolutely zero.

When either of the green LED`s is lit alone, the error lies between 1 to 7 bits. When one green
and one yellow LED is lit, the phase error lies between 8 to 15 bits, etc.

When the lights are up, this indicated positive correction (Master is ahead)
When the lights are down, this indicated negative correction (Slave ahead)

The above notes hold for positive reference giving forward rotation. Everything is reversed for
negative reference giving forward rotation.

12. Remarks about Drives, Encoders, Cables, Installation

12.1 The drives in use must be dimensioned correctly in respect to power and dynamics required.
The CT 150 can never provide good operation outside the physical limits of the drives.
Prior to connecting the master and the slave to the controller, both drives must be adjusted for a
proper stand-alone operation with no oscillation, by means of a remote speed reference
voltage. The reference inputs must be potential free.

12.2 You must strictly observe all rules and specifications given in the drive manual and all general
safety and installation standards. Use shielded power cables for the motors. Keep distance
between power cables and electronic cables. Put filters to all inductive equipment installed in
the same cabinet (i.e. RC filters in parallel to coils of AC contactors, diodes in parallel to
electromagnetic DC values etc.) Make sure your cabinet and your machine have a solid
earthing/grounding system. CT150 possesses excellent features with EMC immunity, but it can
fail under poor electrical environment conditions.
Keep strictly to the instructions for screening given in section 4)!

25
12.3 The resolution of the TTL-encoders, in principle, should be as high as possible, in order to
keep the mechanical phase error as small as possible when the controller "plays" a few encoder
increments around the zero error position. However it would be nonsense to choose the number
of ppr much higher than needed or reasonable. If, for example, a gear box with several 0.1 mm
of clearance is installed, a 0.01 mm resolution of the encoder could cause slight stability
problems, which needed to be removed by the "Corr-Div" error divider again.

The CT 150 loads each encoder channel with a current of 12 mA. For this reason, one encoder
is unable to supply the impulse input of several target units at a time, as needed with some multi
drive systems. In such applications, our impulse distributor type GV 150 must be used to feed
several controllers from one encoder.

Encoder 1
IN 2
3
GV150 out
4
5 ( cascadable )
6

Fig.33

Please note, that not all types of cables are suited to transmit frequencies as high as 300 kHz!
However, with proper installation and screening, the RS 422 lines provide perfect transmission
even over long distances.

The cross section of encoder cables must be chosen with consideration of voltage drop on the
line. The CT 150 provides a 5.5 V encoder supply and at the other end the encoder must at
least receive it‘s minimum supply voltage! (See encoder specifications).
Please observe the unit accepts at maximum 300 kHz of encoder frequency.

12.4 If you need to switch electronic signals by relay contacts, it is necessary to use relays with gold
contacts. For impulse or analogue switching, we recommend the use of our electronic matrix
switch type GV 155.

13. Steps for commissioning

In principle, all commissioning could happen without a PC, just by use of LCD and keypad.
Since, however, things go much easier and faster, we recommend you to use the OS30
operator software and follow the subsequent steps.

13.01 At this time you must be sure your cutting roll drive is adjusted for proper operation and
maximum dynamics. Remove any ramps and delays from the drive because the CT150
controller will produce the ramps. Make sure the drive can run the maximum speed with a
speed reference of 9 Volts already (We must leave 1 Volt of output swing for the CT150 to
make corrections).

13.02 Make sure all connections are correct and DIL switch S1 is set according to need.

You must be sure your cutter drive runs forward (direction of the line) when is receives a
positive voltage. If not, you must change this on your drive now.

26
13.03 Power the unit up, connect the serial cable to the PC and start the OS30 software.

13.04 Set all registers according to need.

The following registers must be set to initial values like shown:

Length : = Circ 2 Mode : 1

Corr-Divider : 1 Add Cor : 1
Vmax / Vline : 8 Gain Cor : 200
+/- Sync : 00.0 Gain Tot : see table
Unit NR. : 11
Baud Rate : 0
Ser Form : 0
Fig.34
The initial Gain Tot setting depends on the expected maximum frequency of the line encoder
(frequency in KHz at maximum line speed)

f max Gain-Tot
1 KHz 200 000 For frequencies between
3 KHz 66 000 use interpolated values.
10 KHz 20 000 Initial setting can be
30 KHz 6 600 approximately.
100 KHz 2 000

Fig.35

Setting of registers “Mast-Dir“ and “Slave-Dir“ is not important at this time.

Click “Transmit All“ and then to “Store EEProm“ to store your settings to the CT150
controller.

27
13.05 We must first set the counting direction of the encoders. Select the “Test“ function in the
“Tools“ menu.

Click to the “Master Direction“ field. Rotate the Master encoder in forward direction, e.g. the
direction it will rotate later with the material. The counter in the Master Direction field must
count up. Where you find we count down, click “Change direction“.

When we count up, click to the “Direction Slave” field.

Warning: Your cutter drive will get a speed reference of 2 Volts via ramp while you click. It
will start immediately when the drive is enabled! This test speed depends on the Gain-
Correction setting (200=2Volts) and you can reduce it if required for this test. However, for
further steps it is necessary to set Gain-Correction to 200 again.
Also the “Direction Slave” counter must count up. Where you find we count down, click
“change direction“. When we count up, click to any other field to stop the carriage drive again.

13.06 Where you use the parallel interface for length preset (e.g. with a remote BCD switch or a
PLC data output), please click to the “Parallel Interface“ field and verify the parallel data
arrive correctly.

13.07 Click “Exit“ now to return to the normal screen. This will save the settings in the controller.
Next, you should check if the control inputs you use operate correctly. Apply all signals like
“Reset“ or “Start/Stop“ and see if the signal change is visible in the “external“ column of the
Inputs field of your screen. Especially it is important to check the ”Cutting Pulse”. The
corresponding indication box in the external field must go either ON or OFF while your tool is
approximately in it’s cutting position. Please remind the Cut-P2 and P1-Cut settings refer to
the rising edge of the cutting pulse (when indicator switches from ”OFF” to ”ON”).

28
13.08 As a next step, we must set the Gain Total value for the analogue feed forward signal. Make
sure the cutter drive is enabled to run, then select the “Adjust“ function in the “Tools“ menu.
Please run the Master encoder at low speed and see how the cutter roll follows.

We must observe the colour bar graph and the differential counter now while we adjust the
“Gain Total“. Gain Correction should always be set to 200 during this procedure.
When we click the Reset to “ON“, our differential counter will show zero and the bar graph will
be in it’s green center position.
When we click the Reset to “OFF“, our differential counter will run away and the bar graph will
move to one or the other direction.
We must find now a setting for Gain Total that keeps our counter close around zero (i.
e. -5....0....+5) and the bar graph in its green/yellow center position.

• When the counter counts to positive (bar graph moves to right):

Gain Total is too low and must be increased.

• When the counter counts to negative (bar graph moves to left):

Gain Total is too high and must be reduced.

• For important changes of Gain Total use the slide button in the Gain Total field.
For fine tuning, use the and buttons.

13.09 When Gain-Total has been set correctly, we must now adjust Gain-Correction.
The rule is to have Gain Correction as high as possible. Typical values are from 300 to 1000,
sometimes even 2000. Where you find your drive starts oscillating or running roughly, reduce
Gain Correction again until we have stable operation. To change Gain-Correction, use the
slide button or the and keys of the corresponding field.

29
13.10 We now can exit the Adjust Menu and return to the main menu. The machine is ready to cut
and we can simulate automatic cutting cycles.
It is important you start your first trials with a length setting equal to the circumference 2 -
setting. This ensures your cutting roll rotates at constant speed with the circumferential tool
speed always synchronous to the line. Then try to change the length setting. The more your
settings moves away from the „“circ2“ value in one or the other direction, the more distinct you
will see the speed profile of the cutter roll. All the time, the front LED’s on the unit and the
colour bar on the PC screen should move around the green/yellow center range.
13.11 It is recommendable to observe the cutting cycle by the oscilloscope function of the operator
software. Select ”Oscilloscope” in the Tools menu. Set the serial code of channel 1 to :1 to
see the cutting error. Set the serial code of channel 2 to :2 to see the speed profile.

14. Hints to improve performance

The performance of the electronic control system is clearly indicated by the front LED’s and the
colour bar with differential counter on your PC screen. When you have achieved settings to
keep the LED’s at the green/yellow center position at all line speeds and with all length presets,
there is nothing to improve.
If, despite of this, your cutting results should not satisfy you in terms of accuracy or
synchronism, there are definitely mechanical or other reasons outside of the control loop.
The following hints refer to improvements you can make when LED and differential counter
indicate unusual characteristics:
14.1 Many of the front LED’s are lit at the same time and the differential counter shows very
unstable values:
• The resolution (ppr per length unit) of one of the encoders could be much higher than the
mechanical clearance of your gears / toothwheels etc.
• reduce edge count setting from (x4) to (x2) or (x1)
• See register ”Correction Divider”
• Reduce “”Gain Correction” setting if this eliminates the problem.
Remark: Even though your LED’s can indicate a very unstable characteristics, your cutting
accuracy and performance may be good. Then just accept this visual flaw.

30
14.2 The LED’s and the differential counter move up and down with the speed cycle of the
cutter.

• Try to increase the “Gain-Correction“ setting

• Check for avoidable ramps and delays in your drive
• The cutter drive is not strong and dynamic enough to follow the speed profile or to bring
enough torque at the time the tool penetrates the material
• Reduce line speed for length settings where you observe this.

Remark: This must not really affect your cutting performance. When the accuracy is good, you
can accept this visual flaw.

15. Physical Range of Cutting Lengths

The possible range of cutting lengths depends on several mechanical and electrical parameters
like roll diameter, line speed, synchronous zone and dynamics of the drive. There is no
limitation from the CT 150 controller. This unit calculates at any time the longest ramps possible
to achieve the desired cutting result. As soon as these ramps become so short that the drive is
unable to follow, we run to the physical limit.

The subsequent formulae should help you to optimise the layout of your cutting machine or to
calculate what is possible or impossible. It is assumed that the cutter drive could run the double
of maximum line speed ( Vmax / Vlin = 2 ). In situations where the cutter can take higher
speeds, or where we can reduce line speed at extremely short cutting lengths, it is possible to
cut shorter pieces than given by the formulae.

The following abbreviations are used:

U = Circumference of the cutter roll ( mm ).

v0 = Max. line speed in mm per second.

l sync = length of the synchronous phase ( mm )

tH
= shortest time the drive needs to accelerate the roll from line speed to
double line speed ( sec. ).

tL
= shortest time the drive needs to decelerate the roll from synchronous
speed to standstill ( sec. ).

l = actual cutting length ( mm ).

L1, L2, T1, T2 = Reference values for calculation.

15.1 The shortest length possible ( l min )

First we must calculate the reference time T1:

U − l sync
T1 ( sec ) =
9 v0
When t H is lower or equal T1:

l =
( )
7 l sync + v 0 t H + U
(mm )
min
8

31
 When t H is higher than T1:

l min = l sync − 27 v 0 t H + 2
7 (
v 02 t H2 + 7 U − l sync )v 0 tH ( mm )
15.2 The longest length possible ( l max )
First we must calculate the reference time T2:

U - l sync
T2 =
v0

When t L is lower or equal T2, there is no limitation for long lengths.

When t L is higher than T2, the longest length is:

l max = l sync + 2 v 0 t L − 2 ( )
v 02 t L2 − U − l sync v 0 t L ( mm )
15.3 Dynamic requirements for the roll drive

The subsequent formulae show what the drive must be able to execute in therms of
acceleration / deceleration, when the cutting parameters are specified.
First we need to calculate two reference length values:

2U + 7l
L1 =
sync
( mm ) L2 = 2U − l sync ( mm )
9
For all cutting lengths smaller or equal L1:

8 l - 7 l sync − U
tH = ( sec )
7 v0

For all cutting lengths longer or equal L2:

U − l
tH =
sync
( sec )
v0

For lengths between L1 and L2 we get:

tL =
1
•
(l−l sync ) 2

tH =
7
•
(l−l sync ) 2

4v 0 U−l 4v 0 U−l

32
16. General Master Reset and Erase of EEProm

The unit carefully checks all entry data for validity and correctness within their permitted
numeric range. If, as an extreme exception, invalid data should intrude into the register range,
bad function or even a full hang-up could be the result. If this should ever happen

• push the Reset button on the unit‘s front (accessible by a small screw driver only)

or

• power down the unit and power up again after a few seconds.
Both measures result in a complete reconfiguration of all ports and registers. RAM and
buffer data will be lost and the unit restores all data from the EEProm.

If, however, invalid data should have penetrated to the EEProm, even the previous steps
will not help. In this case:

• switch off the unit

• set the slide switch PRG/RUN to the PRG position

• keep key A down while powering on the unit and keep it down for at least another 5 sec.

This will clear up all the EEProm to it’s minimum values, and all registers need to be setup
once more.

Above steps represent an emergency procedure that you will never have to apply under
regular conditions. In an extreme case however ( i. e. lightening-strike in the factory etc. ) they
could help to get the unit working again.

33
17. The BY 106-X Remote Thumbwheel Switch

BY106
72,5 mm

X2 X2
max. 1,5 1 2 3 4 5 6 7 8 9 10 11 12

X1 1 2 3 4 5 6 7 8 9 10 11 12 X1

2 Screwterminals,
12 positions each
DEC.1 DEC.2 DEC.3 DEC.4 DEC.5
- - - - -
24 mm
+ + + + +

A
B

23 mm

Panel Cut Out

Switch Type No. Decades A ( mm ) B ( mm )

BY 106 - 3 3 59.5 57

BY 106 - 4 4 59.5 57

By 106 - 5 5 74.5 72

Fig.36

1 +12V *
X2/1 * Switch supply

S1 14
Select- S2 2
lines S3 15
S4 3
BCD 1
16 X2/11
BCD 2 ( LSD )
4 X1/11
BCD 4
17 X2/12
BCD 8 -4
5 X1/12 10

BCD 1
18 X2/9 Remote
CT 150 BDD 2
6 X1/9 switch type
( PI ) BCD 4 -3
19 X2/10 10 BY 106-5
BCD 8
7 X1/10 or
BCD 1 PLC Control
20 X2/7
BCD 2
8 X1/7 -2
BCD 4 10
21 X2/8
BCD 8
9 X1/8
BCD 1
22 X2/5
BCD 2
10 X1/5
BCD 4 -1
23 X2/6 10
BCD 8
11 X1/6
BCD 1
24 X2/3
BCD 2
12 X1/3
BCD 4 0
25 X2/4 10
BCD 8
13 X1/4 ( MSD )

SUB-D Connector 25-pin Screen Screwterminal

Fig. 37

34
18. Dimensions and Specifications

9
5,5
2,5

1 RS232
2
3
4 PI
5
6
7 PI/PO
8
122,5
128,6

RES

7
3
1 2

111
50

MASTER SLAVE ANALOG

171
55,5 188
70,5
Front view 194
Side view
14
70

7
14

Top view

Rear view

Fig 38

35
 Power supply : 18...30 V unstabilised

Consumption : approx. 300 mA ( plus 25% of the encoder supply currents, if

internal encoder supply used )

Encoder Supply : Aux. voltage 5,5 V, max. 500 mA installed

Processor : H8/532 with 20 MHz clock frequency

PCB and Technology : SMD, Multiplayer PCB`s, High speed logic 74 HCT

Encoder Inputs : Two A, A', B, B', Z, Z' (5 V TTL opto-isolated)

Low < 0.8 V, High > 3.0 V (4.0 V with differential input signals)

Other Inputs : 1 parallel port PI ( 24 lines )

1 control port ( 12 lines )
all PNP with 18 - 30 V level.

Serial link : RS 232, RS 485 (CAN-interface optional)

Absolute max. frequency : 325 kHz

Response time : approx. 150 µsec

Analogue In/Out : 3 inputs +/- 10 V ( Ri = 100 kOhms )

3 outputs +/- 10 V ( Imax = 5 mA )
Resolution: 12 Bit ( = 4096 steps )

Analogue Correction
Saturation : 10 Bit = 1024 error increments

Error memory : 32 000 error increments

Control Outputs : 8 transistor outputs (opto-coupler 30V/75 mA max)

Speed error : +/- 0,00 (absolute)

Cutting accuracy : Typical +/- 5 encoder increments

Operating temperature : 0...45 °C

Dimensions : see drawing

Weight : Approx. 850 g

19. History

Name
Version Date: Page: Changes / Supplements:
:
CT15013 TJ Oct. 03 23/24 Control word and status word
N 36 Encoder inputs levels and max. frequency

36