CENTER GUIDE CONTROLLER

!" ##
 While every precaution has been taken in the preparation of this document,
assumes no liability for any error or omission it
may contain or for any damages resulting from the application or use of the information
herein.

reserves the right to change the

characteristics of its products and services at any time in order to incorporate the latest
technological developments. The information contained in this document is therefore
subject to change without notice.

This document is property of Hence

this document may not be reproduced or copied, in whole or in part, in any form or by
any means viz. graphic, electronic or mechanical including photocopying, recording or
storage and retrieval system.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 01/18

1
 CHAPTER 1 : INTRODUCTION

CHAPTER 2 : INSTALLATION AND PRECOMISSIONING CHECKS

CHAPTER 3 : CALIBRATION

CHAPTER 4 : ELECTRONIC SYSTEM DETAILS.

1. PHOTOSENSOR
2. SIGNAL CONTROL MODULE CTS 11
3. SERVO VALVE CONTROL MODULE CTV 21
4. LOGIC CONTROL MODULE CTL 31
5. POWER SUPPLY MODULE CTP 41
6. MOTHER BOARD CTM 02

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 02/18

2
Today high productivity is the main goal of all continuous strip-finishing lines. This can
be achieved with high line speeds, but sometimes it becomes a restriction, working
with high line speeds. This restriction is mainly because of strip behavior e.g. lateral
movement & when the guides are not properly designed and applied. At higher line
speeds, the strip behavior amplifies the problem in strip tracking and it becomes very
essential to control the lateral movement of strip.

The maximum production output in the continuous strip finishing lines is possible only if
all the machines are working with desired specifications. An automatic strip guide
system can compensate the deficiencies / minor misalignments in the line. The
important problems which demand the use of automatic guiding are -

1. Inadequate strip tension.

2. Strip shape.
3. Improper machine alignment
4. Uneven pinch roll pressure
5. Excessive roll run-out pressure.

Continuous improvements in these major problem areas have been made in recent
years. The longer lines, increasing line speeds and high accuracy demand of lateral
strip positioning, requires a well designed and well applied automatic strip guiding
system.

Where the uncoiler and recoiler guiding system is well accepted in the industry, with
increase in line length and speed of modern continuous strip finishing lines, the lateral
movement of strip becomes severe which necessitates of intermediate guiding system.
The primary purpose of intermediate guiding is to maintain the strip approximately in
the center of the line.

The different guiding systems presently used in the industry are-

1. End pivot guide and center pivot guide.

2. Kamberoller guide system.
3. Offset pivot-guide system.
4. Uncoiler guiding.
5. Recoiler guiding.

Today all the automatic guide control systems are based on the closed loop systems
with very good quality electronic signal processor, valve drivers and a feedback system
from the field.

PUNE-14. PH. 020 27013095

REV. SH. No.

3
 Make a return loop in the hydraulic system by bypassing the hydraulic cylinder.
Remove the hydraulic servo valve and keep safely. Fix an oil flush plate in place of
servo valve. Disconnect the power supply to the electronic card rack. Switch ON the
mains power to the control cabinet and measure voltage at the incoming terminal
(Refer to the wiring diagram). Verify that it is in the permissible limits & make a record.
Start the hydraulic pump unit and check the direction of rotation of motor. If the
direction is reverse interchange the connection of any two phases.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 04/18

4
 Keep the pump running along-with the external filtration system of oil to remove the dirt
from the piping. Continue the filtration for a minimum period of 2 hours.

Replace the hydraulic Servo valve on the system. Switch ON hydraulic pump and
check that the pressure builds up to desired value.

Change the hydraulic oil filter if there is any optical or electrical signal. Check the
hydraulic oil periodically for dirt particles and change it after 10000 hours of operation.
Repeat the filtration cycle for every fresh oil fill.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 05/18

5
 Switch on the hydraulic pump unit and switch the power supply to electronic processor
modules.

DO NOT SWITCH ON ELECTRICAL POWER SUPPLY TO HYDRAULIC SERVO

VALVE UNLESS IT IS UNDER HYDRAULIC PRESSURE. GIVING POWER
SUPPLY TO SERVO VALVE IN ABSENCE OF HYDRAULIC PRESSURE CAN
LEAD TO DESTRUCTION OF THE PILOT STAGE.

SWITCH OFF THE POWER SUPPLY TO ELECTRONIC MODULES WHILE

INSERTING IN OR TAKING OUT OF THE CARD RACK.

Switch ON power supply to the fluorescent lamps. Before carrying out any adjustment
on photosensors, allow the fluorescent lamp to warm up for at-least 30 minutes. The
power supply to lamps is given through the CVT (Constant voltage Transformer). This
will eliminate the variation in the intensity of lamps due to the supply voltage variations,
because output of CVT is constant irrespective of supply voltage variations (within
tolerance limit).

Take out all electronic control modules. Insert power supply module CTP 41 over the
extension board placed in the mounting rack and switch on the power supply.

Check the power supply -12 V DC and +12 V DC +/- 0.5 volt at TP3 and TP4 against
TP2 0 V (analog ground). The same test points are available on the Mother board
CTM02 also. The LED V1 & V2 lit when both the power supply are OK.

Switch ON power supply to the fluorescent lamps. Insert the signal control module
CTS 11 over the extension board placed in the mounting rack. Switch ON the power
supply to the electronic controller. Check the power to the sensors in the junction box
mounted on sensor frame.

RED : +12 V
YELLOW : -12 V
BLACK : 0V
GREEN : OUTPUT OF SENSOR 1
BLUE : OUTPUT OF SENSOR 2

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 06/18

6
 Connect the multimeter between the output of photosensor 1 and 0v with proper
polarity and check voltage signal.

Photosensor 1 blocked to light : -1.65 V approx.

Photosensor 1 open to light : +2.50 V approx.

The output of photosensor 1 can be adjusted by (use a small size screwdriver)

adjusting the potentiometer accessible through the small hole on the body of the
sensor. Adjust required voltage with photosensor 1 open to light.

Repeat the above procedure for photosensor 2. Adjust both the sensors for the output
voltage as close as possible.

This adjustment has to be done with simulation strip (strip width same as that of the
distance between photosensors). Bring the strip in centerline of the sensing frame.

Measure the output signal of both the photosensors against 0V. Theoretically there
should not be any deviation in output signal of both the photosensors, even though,
there could be difference of +/-100mV to +/-150mV in two output signals. Assume one
photosensor as reference and adjust the output signal of other photosensor to that of
reference.

If there is a very large deviation in output signals there could be a misalignment of one
or both the sensors. Check & align both the sensors properly. Photosensors should be
mounted perfectly perpendicular to the tube lights as well as plane of both
photosensors perpendicular to the centerline of the machine.

After adjustment check again with stimulated strip. When both photosensors output
signal equalizes the adjustment is over.

NOTE

AFTER CHANGING THE FLUORESCENT LAMP, THE ADJUSTMENT HAS

TO BE REPEATED AS PER ABOVE INSTRUCTIONS. IF ONE
FLUORESCENT LAMP IS FAULTY, IT IS RECOMMENDED TO CHANGE
BOTH THE LAMPS IN THAT FRAME.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 07/18

7
 With simulation strip the adjustment of Signal Control module CTS 11 has to be carried
out. Check the output signal of both the photosensors (with simulation strip in the
sensor frame) which is input signal to Signal Control module at TP9 & TP10 against
TP2 (analog ground). Both values should match as close as possible.

The output of signal processor at TP11 is a summation signal of two photosensors

output.

Check the output signal of difference amplifier at TP12. This should read 0V. The
balancing of this output can be achieved by means of the front potentiometer P2 on
fascia. Record the values of TP9, TP10, TP12 & position of potentiometer P2.

The dual color LED V2 should unlit which indicates null signal.

Check the stroke of the linear position transducer i.e. linear potentiometer. Remove the
hydraulic hoses connected to the hydraulic cylinder. Shift the movable frame of the
center guide manually over the fixed frame & locate the position where the shift of
movable frame w.r.t. fixed frame is equal to the stroke of linear potentiometer. Go
below to the position equal to 90% of the stroke & fix the linear potentiometer using the
angle clits. There are spherical ball joints at both ends of the linear transducer, which
helps to absorb minor misalignments in mounting. While fitting maintain the plain of the
potentiometer parallel to the members of the movable & fixed frame. Fix the hydraulic
cylinder hoses back to their positions.

Switch ON the hydraulic power pack. Adjust roughly, the movable frame manually to
the center position of the line. This can be verified by the stroke of piston rod of
hydraulic cylinder, which should be half in & half out.

Insert the module CTS11 over the extension board placed in the mounting rack. Switch
ON the power supply. Check the output voltage of the linear potentiometer at TP7
against TP2 (analog ground). At this center position of frame & potentiometer voltage
at TP7 should read near 0V.

Switch the guiding system into the Servo Center mode by the selector switch.
The balancing of the Center position is to be done by means of the potentiometer P1
on the fascia of CTS 11. At balanced position the Servo Center output signal for servo
valve at TP8 should read nearly 0V & dual color LED V1 should unlit. Record the
position of P1, value of TP7 &TP8.

The gain of the system can be adjusted by potentiometer R8 on CTS11. This

potentiometer R8 should be set such that, there are no oscillations of hydraulic
cylinder.

If the direction of hydraulic cylinder is wrong, change the jumper position in S2

mounted on CTS 11.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 08/18

8
 After balancing the photosensors and the Servo center transducer the adjustment of
servo valve control module CTV 21 can be done for different operation modes with
logic control module CTL 31.

Switch the guiding system in Manual mode by the selector switch. Insert the module
CTV 21 over extension board placed in the mounting rack. Check that LED V2 (manual
mode) glows on the CTL 31 fascia.

Adjust the speed of displacement of the frame for LEFT and RIGHT movement by
using the potentiometer R18 and R20 mounted on the CTV 21 module. Measure the
current through the servo valve in both the directions & record the values.

Switch the guiding system in automatic mode by using the selector switch. Check that
LED V1 (automatic mode) glows on the CTL 31 fascia.

The switch S1 provided on the fascia of CTV 21 module, could be used to get the
guide loop amplification in two stages.

S1 in down position : Low range of amplification. Possible adjustment is 0 to

6 times amplification by means of front potentiometer P1 of CTV21.

S1 in up position : High range of amplification possible adjustment is 4 to

200 times amplification by means of front potentiometer P1 of CTV 21.

When material is running through the machine adjust the potentiometer P1, the guide
loop amplification, in such a way that there are no oscillations of hydraulic cylinder.
Record the position of potentiometer P1.

Manual left and right operations are permitted during Automatic control until manual
operation persists.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 09/18

9
 1. PHOTOSENSOR

2. SIGNAL CONTROL MODULE CTS 11

3. VALVE CONTROL MODULE CTV 21

4. LOGIC CONTROL MODULE CTL 31

5. POWER SUPPLY MODULE CTP 41

6. MOTHER BOARD CTM 02

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 10/18

10
 This photoelectric sensor uses the principle of changes in the conductance of a
photoresistor due to change of light intensity falling on it. The sensor gives a current
output, which is not susceptible to electric noise in the field.

This photosensor uses a photoresistance. The change in light intensity of normal

fluorescent tube light falling on the photoresistance will reflect a change in the
conductance. The angle of view of sensor is 35 deg. There will be no effect on
performance of sensor for the variation in the ambient light as the sensor is designed
to sense light only from the fluorescent tube, when properly aligned.

The photoresistance is fed with +12 volt power supply on one side and the change in
the conductance is converted into an electric signal, which is amplified by operational
amplifier A1. The potentiometer assessable from outside (through a 3mm-size hole on
the body of the sensor) can be used to vary the gain. This output voltage of first stage
of operational amplifier is passed through a high stop filter. In the second stage of the
amplifier the voltage signal is converted into a current signal of 0 to 5mA, when the
sensor is from fully blocked to unblocked stage of light. A 4 core wire is used for the
power supply & output connections of sensor.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 11/18

11
 This module controls and processes the signals from servo center transducer and
photosensors used for sensing strip edges for center guide control or edge guide
control applications.

• Jumper S1 is not required.

• Resistance R4, R49, R51 are not required.
• Power supply to the potentiometer can be realized through bz10 and bz12.
• Connect wiper point of potentiometer to bz18.

The power supply to the potentiometer measured at TP5 and TP6 is -3.6 volts and
+3.6 volts respectively and is derived from R56, Z2 and R55, Z1. The potentiometer
output at the wiper point can be measured at TP7 and is fed to operational amplifier
U1A as a position signal. With wiper point at the center position of linear
potentiometer, signal should read nearly 0 volt. The O/P of operational amplifier U1B &
U1C i.e. at TP8 can be balanced by the front potentiometer P1 on fascia so as to
reach to center approach signal.

The potentiometer R8 serves the amplification adjustment. The voltage at TP8 can be
inverted by changing the position of jumper in S2.

The operational amplifier U1D controls the dual colour LED and indicates the null
signal.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 12/18

12
 For center guide control there are two Photosensors mounted on the sensor frame.
The power supply to both these photosensor is fed from bz4 (0V), bz6 (-12V) & bz8
(+12V). The output of one photosensor is connected to bz20 and output of second
photosensor is connected is connected to bz22. The conductance changes in the
photoresistance, with variation in the light intensity sensed by the lenses of
photosensor are converted to the current output.

The input at bz20 and bz22, the current output of photosensor is converted into an
analog voltage signal and fed into the operational amplifiers U2A & U3C.

The operational amplifier U3B is a summing of U2A and U3C.The output of summing
amplifier available at bz 24 i.e. at TP11 can be inverted by changing the position of
jumper in S4.

The operational amplifier U2B subtracts (difference amplifier) the voltage signal from
operational amplifier U2A and inverted signal of U3C through U3D. When both the
photosensors are properly balanced for the full light and fully blocked, the O/P
difference amplifier at bz26 should read 0 volt. The front potentiometer P1 on fascia
serves for balancing this output of difference amplifier.

The O/P of difference amplifier at bz26 can be inverted by changing the position of
jumper in S3.

The operational amplifier U2D controls a dual colour LED & indicates the null signal.

The remote offset point signal can be connected to bz28 & intensity of signal can be
varied by potentiometer R33. The offset guide point signal is fed to the input of
difference amplifier.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 13/18

13
 bz14 TP7 : Input of servo center transducer from all 3 types of
transducer.
1. Linear position transducer (potentiometer)
2. Inductive Namur proximity sensor.
3. photoelectric plunger sensor.
bz20 TP9 : Input of photosensor 1.
bz22 TP10 : Input of photosensor 2.
bz28 TP13 : Remote offset guide point
bz2 TP1 : Power ground.
bz4 TP2 : Analogue ground.
bz6 TP3 : -12 volts DC input power.
bz8 TP4 : +12 volts DC input power.

OUTPUT :

bz10 TP5 : -3.6 volts reference output.

bz12 TP6 : +3.6 volts reference output.
bz18 TP8 : Signal output servo center .
bz16 : +12 volts output power to the photoelectric plunger sensor.
bz24 TP11 : Center guide / Edge guide summing amplifier output .
bz26 TP12 : Center guide difference amplifier output guide.

LED V1 RED/GREEN Lit : servo center position off-centered

LED V2 RED/GREEN Lit : center/edge position off-centered.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 14/18

14
 This module controls the hydraulic servo valve operations using current signal.

There are 4 control inputs used for controlling valve output signal.
One for Auto mode for continuos tracking of the strip.
One for Servo Center input for recentering the frame.
Two manual inputs for right and left movement of the frame.
All these inputs are fed to the amplifier through logic control using the analog switches
as per external commands through CTL 31.

The current signal to the valve can be blocked on either extreme position of the frame
using two locking signals LOCK1 & LOCK2.

The current gain can be controlled through potentiometer P1.

The SPDT switch S1 gives a two-fold gain as per figure 2 for two different switch
positions.

b14 Input 1 :
z14 Input 2 : Auto Signal 0 to +/- 10 Volts
b16 Input 3 :

z16 Servo center Input signal 0 to +/- 10 Volts

b18 Auto release +12 V = Level 1, 0 V = Level 0

b20 center release +12 V = Level 1, 0 V = Level 0
z18 Manual Right +12 V = Level 1, 0 V = Level 0
z20 Manual Left +12 V = Level 1, 0 V = Level 0
z28 Lock 1
z30 Lock 2

bz24 Current output for servo valve

bz26 +/- mA Max.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 15/18

15
 This module controls the operator command for Auto/Man/Center operations as well as
the frame locking provisions.

All the operator commands are optically isolated through optocouplers.

There are 6 inputs used for operator and safety controls like Auto, Manual, Right, Left,
Lock1 and Lock2.

There are 6 outputs for Auto, Center, Right, Left, Lock1 and Lock2.

If no input command exists, the center output will be released.

bz20 Lock1 From proximity switch on extreme position of frame

bz22 Lock2 Logic 0 = 0 V, Logic 1= 12V

bz24 Automatic Logic 0 = 0 V, Logic 1= 12V

bz26 Manual Logic 0 = 0 V, Logic 1= 12V
bz28 Right Logic 0 = 0 V, Logic 1= 12V
bz30 Left Logic 0 = 0 V, Logic 1= 12V

bz32 Common 0 V of 24 V Power supply

b14 TP7 Lock 1 - +12 V = Level 1, 0 V = Level 0

b16 TP8 Lock 2 - +12 V = Level 1, 0 V = Level 0

b18 TP9 Auto - +12 V = Level 1, 0 V = Level 0

z14 TP10 Center - +12 V = Level 1, 0 V = Level 0
z16 TP11 Right - +12 V = Level 1, 0 V = Level 0
z18 TP12 Left - +12 V = Level 1, 0 V = Level 0

LED V1 RED Lit Automatic Mode

LED V2 RED Lit Manual Mode
LED V3 RED Lit Center Mode

In Automatic mode, Manual operation can function by operating Right / Left switch,
blocking the Auto mode, until the Manual operation persists.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 16/18

16
 This module regulates the +12 V and -12 V DC output power supply to be used by the
other modules like CTS11, CTV21, CTL31 etc.

The Input power supply would be either 220V or 110V AC 50 Hz. The 220V and 110V
selection is through solderable jumpers. The transformer X1 steps down the input
power to the 15V - 0V - 15V AC. Rectifier U1 converts the AC input to the DC output.
The regulator U2 7812 and U3 7912 regulates the DC output at +12V and -12V DC
respectively.

bz26 )
bz28 ) L AC input power
220 V /110 VAC
bz30 ) 50 Hz.
bz32 ) N

bz02 TP1 Power ground

bz04 TP2 Analog ground
bz06 TP3 Regulated output power -12 VDC
bz08 TP4 Regulated output power +12 VDC

LED V1 RED Lit +12 V DC output power OK

LED V2 RED Lit - 12 V DC output power OK

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 17/18

17
 ! "

This board is used for interconnecting the signals, input/output commands & power
supply between the modules of Center Guide system. The external signals are also
connected through various connectors.

There are various plug-in type connectors mounted on the Mother board CTM 02 as
listed below. There are 4 power Euro connectors for mounting the modules CTP41,
CTL31, CTV21, CTS11. The 24V sugar-cube relays K1 to K4 are used to derive the
hydraulic fault & the system ready signals for external interlocks. The test points TP1
to TP4 are also available on the Mother board for measurement of 0V, +/-12V etc.
Various LED’s show the status of different inputs as given below. The jumper J1 is for
the selection of the Summation or Difference signal of the two photosensors going to
Valve control module CTV21, after processing in the Signal Control module CTS11.

The subsequent block diagram shows the interconnections between the Mother board
& other center guide modules & external connections through plug-in connectors.

X1 : Input Power Supply 110/220V ac.

X2 : Operational Logic command Inputs like LOCK, AUTO, MAN etc.
X3 : Current output to Servo Valve.
X4 : External Reference to Valve control module.
X5 : Power supply & Signal connections to Servo Center transducer.
X6 : Photosensor 1 & 2 Power supply & signal connections.
X7 : Hydraulic Input signals & Hyd. Fault signal for external interlock.
X8 : Electronic System Ready for external Interlock.
X9 : Additional Reference to Valve Control module.

TP1 Power ground

TP2 Analog ground
TP3 Regulated output power -12 VDC
TP4 Regulated output power +12 VDC

LED V1 GREEN Lit +12 V DC output power OK

V2 RED Lit - 12 V DC output power OK
V3 RED Lit LOCK 1
V4 RED Lit LOCK 2
V5 RED Lit AUTO
V6 RED Lit CENTER
V7 RED Lit MANUAL - RIGHT.
V8 RED Lit MANUAL – LEFT
V9, V10, V11 RED Lit Hydraulic Inputs.

PUNE-14. PH. 020 27013095

REV. SH. No.

REV. DATE MODIFICATIONS 0 18/18

18