NW Control and Adjustment Manual Page 1 V.Rakic 26.09.

2014

NW Control and Adjustment Manual

Proper Use
The MICRO GAP control 2000 may only be used to operate, control and monitor Herrmann
ultrasonic welding systems in the nonwoven sector which are used to weld thermoplastics.
Other applications, particularly controlling components for welding other materials, do not
comply with the intended use and may lead to hazardous situations.
Any application other than those described here shall be considered improper.
The manufacturer shall bear no liability in the event of non observance or any ensuing
damage.
Proper use includes both compliance with the information provided in these operating
instructions and all other operating, maintenance and servicing specifications and
instructions belonging to the system. This applies in particular to compliance with all safety
information.
The MICRO GAP control 2000 may only be used when it is in a fully operational condition
under observation of the safety information and potential dangers associated with the device.

Operating Personnel

Qualification
MICRO GAP control 2000 operating personnel must:
• have received instruction in operating the MICRO GAP control 2000 and the Ultrasonic
Welding Machine.
• be proficient in how to handle the MICRO GAP control 2000.
• be aware of and observe the applicable safety stipulations for operating the machines and
systems.
• wear the required protective equipment and be informed of the dangers of operating the
machine in connection with the MICRO GAP control 2000.
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Navigation NW Control
F1, F2, F3 and F4 function keys for activating the four softkeys along the bottom edge of
the display.

←, →, ↓ and ↑ arrow keys for selecting a sub-menu from the main menu, for selecting
entry fields.

ENTER key for confirming an entry. for pressing a button.

Num. keypad : 0 to 9, +/- and dot (.)for entering a numerical value in the corresponding
entry fields.

RESET key for resetting an error (for resetting an entry).

HELP key for calling up the help text for the entry field selected.

Delete key for deleting the character to the left of the cursor when entering a numerical
value in an
entry field.
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Navigation NW Control

The sub menus Recipes, Process, Error Batch and Service can be chosen with the
cursors ↓↑ and accessed with the „ENTER“- key
The function keys (F1..F4) lead to the function screen Setup, Automatic, Home
Position and Zero Adjust

Actuator selection, actual position and force are displayed

The actuators can be driven single or together with a variable step size.
A possible metal contact is shown for all actuators
Testing the zero adjust

Actuator selection, actual position and force are displayed

The target values can be changed single or together with a variable step size
A possible metal contact is shown for all actuators
Buttons “-” / “+” changes the RPM ramp up or down
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Home position status for all actuators.

Move one or all actuators to home position

Force Calibration status for all actuators

Perform the Force Calibration for one or all actuators
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Folders Configuration: Recipes

Recipes=>Enter

Recipe selection (R1..R4)

Information about the available actuators
Activating / deactivating the available actuators
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Folders Configuration: Process

Process=>Enter
The function keys (F1..F4) lead to the Function.
F3 or F4 sliding to another Page.
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RPM Factors=>Edit
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Folders Configuration: Error Batch

Error Batch=>Enter
The error batch contains a list of the last 99 errors
along with precise designation, time and date.
By plugged USB automatic transfer of dates.
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Folders Configuration: Service

System=>Enter
The service menu is used to set service (global data),
actuator (actuator data) and Startup data and to acti-
vate the backup and restore functions.
If password protection is activated, the service menu
can only be accessed by entering the password.
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Folders Configuration: Actuator

Actuator => Enter

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Folders Configuration: Anvil

Anvil => Enter

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Folders Configuration: Initiation

Initiation => Enter

• Configuration of the hardware-settings

• Add a new actuator
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Folders Configuration: Initiation Function CDM &CHU

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Folders Configuration: Special Function

Special Function => Enter

„External Recipe Selection“can only be selected using the
handheld unit and is always deactivated when using an S-
IPC touch screen. Recipes R1, R2, R3 and R4 can be
selected from outside using digital signals. 3 additional digital
inputs and 1 digital output, which can be found on a digital
extension module, are needed for this. The digital extension
module is attached after the last module on the module
carrier. If the module carrier holding the last module is
already full, another module carrier plus the CCL91x
processor module must be used.

The MICRO GAP control includes an integrated Help system. A help window containing a brief description can
be called up for any selected parameter by pressing the 'HELP' key.

Help
Button
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Backup and Restore

All parameter settings can be saved as a backup in the 'Service' submenu (softkey F3).
The backup may be made on the controller or alternatively on a USB stick.
It is only ever possible to enter one backup on the controller while several may be entered on a
USB stick.
When saving on the USB stick, a subfolder with the current date and current time is created in
the 'Backup' folder, which then contains the backup.
Previously saved settings are restored using 'Restore' (softkey F4).

Creating a Backup:

• Insert USB stick.

• Press 'BaUp' softkey (F3).
• Select the storage location:
o USB stick: a subfolder is created with the help of the current date and time in
the 'Backup' folder on the USB stick. This makes it possible to create several
backups.Format: YYYY-MM-DD-HHMMSS, e.g. 2009-07-06-091500
o Controller (SPS):A 'Backup' folder is created on the SPS.
• The controller copies the following files, which contain all settings, to the
corresponding destination folder:
- global.data
- module.data
- modules.data
- recipe1.data
- recipe2.data
- recipe3.data
- recipe4.data

Restoring settings using 'Restore':

• Insert USB stick.

• Press 'ReSt' softkey (F4).
• Select the restore source:
o USB stick:The restore data (the 7 named files) must be in the 'Restore' folder on
the USB stick.
o Controller (SPS):The restore data are in the 'Backup' folder on the controller.
• The controller copies the restore data from the corresponding source folder.
• A message will appear on the manual programming device and the controller must be
restarted.

Use Backup Viewer for Print out:

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Short adjusting for Herrmann Unit (Size change)

1. Please handle carefully!!

2. Remove material from the gap between the Sonotrode and the anvil drum.
3. Move cam mechanism into vertical position. Tight it.

4. Execute return to home position (0 steps). By pressing F3

5. Open main screws but only 4 on the Top do not open the two on the bottom.
Yes

Yes

No

6. Move actuator in Setup Mode (change Step size to 1000) to step position 8000Stp. Pressing F4
increase the Steps.
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7. Unbolt Mechanic cam and leave it unbolt.

7a. Adjust the parallelism with the CAM/Lever until you have Metal contact.
Between the Anvil and the Sonotrode use shims they should be on the maximum widens edges.
Use for this adjustment metal shims 0.05 mm.
Moving Pin on the Top left or right you can adjust Para. ←, →.

7b. After finish tight the UNIT Screws in Cross direction (Wheel Prinzip).

1. Adjust the cam mechanism until the Sonotrode touches the anvil drum (metal contact).
Tight it again when you see M on display.
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9. Execute return to home position (0 steps). By pressing F3

10. Do Calibration (tthis is necessary after every mechanical installation)in Main Menu. By pressing F4

wait for 10sec!!!.

11.Check zero adjustment on position 7000. The value should between 40 –60N.
If not Calibrate again.(Setup =>Step size 1000 => F4 Until 7000)

12.Check the Parameters. The force value should be about (depend of Material) 150N or higher and the
work position should be 7600 Steps.(Main Menu => Process=> Starting Position =>Force)
Also good recommendation for Size change!!!

13.Edit RPM-Factor the Force is changing with the Speed (Main Menu => Process=> RPM-Factor)

14.If the bonding quality is to low then please increase the force( by pressing F4 in Automatic Mode=>
Machine running) or Factor RPM.

Service Password can be provided:

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Lexicon of Welding Parameters

GAP control mode: the controller model can be selected:

2. PID controller: Once the operating position has been reached, control mode starts in this setting.
The controller corrects the position of the actuator to adapt the actual value to the target value.
3. Position (no controller):In automatic mode and when a start is undertaken, the equipment only
moves to the operating position when using this setting.

Metal Contact: the type of metal contact monitoring can be set:

1. off:no machine deactivation in the event of metal contact.

2. strict:machine deactivation in the event of metal contact.
3. smart (reduced MC sensitivity):in the event of metal contact, the actuator is moved back by the
parameter 'Steps back when MC'.This setting is only available for the selected PID controller
model.

Starting position means: when the machine stops, the equipment moves to the starting position.

Operating position means: when the system starts, the equipment moves to the operating position;
once the position is reached, control mode starts and the operating position is automatically adjusted
so that target and actual value are adapted. The equipment always moves to operating position plus
'Deviation from Position'; the operating position is displayed in the 'Position' column in the automatic
mode display.

'Min.contr.pos' means:If this position is exceeded during active control, the machine stops and an
error is output.
'Lower lim. pos (lowest point)' means:lowest permissible point which cannot be exceeded; travel
limit set by software limit switch.

Steps for/back: XXXX stp

'Steps forward / back' means:
the target position is changed by this amount when pressing the '-' key (F3 ) or '+' key (F4) in the
automatic mode screen.

The controller factors are defined in this screen:

- P-Portion: XXXX stp/N (Step/N)
- I-Portion: XXXX stp/N (Step/N)
- D-Portion: XXXX stp/N (Step/N)
Changes impact on the controller characteristics, the controller behaviour; see controller model PID
section. Welding data menu 'Target values', when the 'PID' control mode has been selected

Target Value: XXXX N is the specification for the controller as to what force value (in N) the actuator
is to achieve; the target value appears on the automatic display under 'target value'.
Force +/-: XXXX N means: the target force value is changed by this amount once the '-' key (F3) or '+'
key (F4) is pressed on the automatic display
RPM-Factors: edit to change the RPM factor, move into the next screen by pressing the ENTER key.

Deviation f.Po: XXXX stp Deviation from Positon means: the current operating position plus this
parameter is used as the operating position for the next machine start.
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Stp.back if MC XXXX stp Steps back when metal contact means: if the 'Metal contact' parameter
has been set to 'reduced', then the actuator in question is moved back by this parameter when metal
contact occurs.
Max.Stepsize: XXXX stp max. approach, means: limit value of actuator adjustment value per control
cycle.

Limits

• Limit 1: XXXX N
• Limit 2 XXXX stp
• Limit 3: XXXX N
Meaning: The controller signals 'good' for the first time when the difference between the target and
actual value is less than limit 3. The suspect signal appears when the difference between target and
actual value is greater than limit 1 or the adjustment value is greater than limit 2. The suspect signal
has a higher priority than the good signal (also refer to 'Controller model PID' section).

- Force cal.Pos: XXXX stp Force calibration position means: parameters can be set for the position
at which the force sensor is adapted. Standard value: 7000 steps for 20kHz actuators.Please note:
changes to this parameter only take effect the next time a force calibration is undertaken.

- Force calibration: Reset Pressing the 'Reset' button sets the force offset to '0'. If grouping is
activated, this function affects all actuators and if grouping is not activated, only the actuator selected.

- Mo.ti.horn-Pos: XXXX ms Monitoring time horn position (in milliseconds) for machine
movements means that the actuator movements must be completed within the time displayed
otherwise an error message will appear.

Retr.f.splicing (retraction height): XXXX stp 'Retraction for splicing' means: retraction height for
splicing (in 'steps'); if 24 V are applied at the 'material exchange' input of the controller (while the
machine is in automatic mode), the actuator moves up by the step size indicated here and for the
time displayed at 'Time for Splicing'. The dwell time is at least as long as the signal is applied.

- Time f. splici (dwell time): XXXX ms 'Time for splicing' means: dwell time for splicing (in
milliseconds); if 24 V are applied at the 'material exchange' input of the controller (while the machine is
in automatic mode), the actuator moves up for the time displayed here. The dwell time is at least as
long as the signal is applied. if no signal is applied any more, the actuator remains in this position for
the entered time for splicing and then returns to operating position.

Sensor type: 10 kN / 2 kN= the force sensor used: 10kN or 2kN.

Filter type: 10 Hz / 100 Hz / 1000Hz Filter setting for force sensor.Sensitivity:10 Hz = low 100 Hz =
medium 1000 Hz = high

Measure Range: XXXX N means: the maximum permissible force value should be entered. When
using a 10kN sensor, the value is 2500 and with a 2kN sensor, 500 must be entered.

Min. Value: XXXX N means: The 'minimum value' is the lowest permissible force value during active
control. If the force falls below this value, the system stops and an error is output.

Max. Duration: XXXX N means: As soon as metal contact lasts longer than the time period set here,
an error signal is generated and the actuator is moved away from the roller (anvil).

- Max. contacts (permissible contacts): XXXX N means: permissible contacts per time interval: the
number of metal contacts, shorter than the maximum period, are counted during a time interval (which
can be set). If the limit value specified here is exceeded, an error signal is generated and the actuator
is moved away from the roller. Please note: if one of these metal contacts however exceeds the
maximum period, an error will be produced immediately.
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- ... per time int: XXXX N means: Time interval '...per time': the value entered here determines the
time interval on which observation of the metal contacts is based. Please note: the metal contact
counter is always updated once this time interval has lapsed.

Speed Sensor: pulse / analogue means: selection of sensor type used for recording speed.
1. pulse = speed measured with the trigger sensor
2. analogue = speed measured using an analogue 0..10 V signal which corresponds to
production speed.

Synchronization = on, means:the trigger sensor detecting speed is activated; in this case the
controller operates if it receives a speed impulse; controlling actions are carried out less frequently at
low speeds than at high speeds (controlling actions means comparison of target/actual value and
moving the step motor forward or backward).
Synchronization = off, means:the controller continuously repeats the control cycle. One control cycle
lasts 10 ms for all actuators.

- Switch to Sync: XXXX rpm Changeover to synchronization means: if this value is greater than '0',
synchronization is only activated once this speed is reached (when synchronization = on). Below this
speed, synchronization is automatically deactivated. At '0', the function is deactivated.
Recommendation: this value should be set to '0', i.e. deactivated because if a value greater than '0' is
selected, the roller and converter may under certain circumstances or damaged.

Op.Pt1: XXXX mV / XXXX rpm

Op.Pt2: XXXX mV / XXXX U/min
Rev.det.Limit.: XXXX rpm
Op.Pt = pair of valuesRev.det.limit = revolution detection limit
As well as measuring speed by evaluating signals from the impulse sensor, another alternative is to
measure speed by evaluating an analogue tachometer.
With an analogue tachometer, the characteristics can be entered using 2 pairs of values (Op.Pt1 /
Op.Pt2). A revolution detection limit (rev.det.limit XXXX rpm) can also be entered and speed will not
be recorded below this level.
In order to measure analogue speed, the controller needs an analogue voltage signal of e.g. 0 - 10 V
DC. This voltage must correspond to the machine speed of the ultrasonic roller.

Max time / Rev: XXXX ms' Trigger monitoring time' means:the trigger monitoring time is the time (in
milliseconds) during which a trigger impulse must be made for speed detection (when synchronization
= on only). A trigger impulse must be detected within the displayed time, otherwise the error message
'no synchronization' appears and the machine switches off.