Flying Shear: User Guide

EF
User Guide
Flying Shear
Software for
Unidrive Classic
Part Number: 0460-0078

Issue Number: 4
www.controltechniques.com
Safety Information
Persons supervising and performing the electrical installation or maintenance of a Drive
and/or an external Option Unit must be suitably qualified and competent in these duties.
They should be given the opportunity to study and if necessary to discuss this User Guide
before work is started.
The voltages present in the Drive and external Option Units are capable of inflicting a
severe electric shock and may be lethal. The Stop function of the Drive does not remove
dangerous voltages from the terminals of the Drive and external Option Unit. Mains
supplies should be removed before any servicing work is performed.
The installation instructions should be adhered to. Any questions or doubt should be
referred to the supplier of the equipment. It is the responsibility of the owner or user to
ensure that the installation of the Drive and external Option Unit, and the way in which
they are operated and maintained complies with the requirements of the Health and
Safety at Work Act in the United Kingdom and applicable legislation and regulations and
codes of practice in the UK or elsewhere.
The Drive software may incorporate an optional Auto-start facility. In order to prevent the
risk of injury to personnel working on or near the motor or its driven equipment and to
prevent potential damage to equipment, users and operators, all necessary precautions
must be taken if operating the Drive in this mode.
The Stop and Start inputs of the Drive should not be relied upon to ensure safety of
personnel. If a safety hazard could exist from unexpected starting of the Drive, an
interlock should be installed to prevent the motor being inadvertently started.
General Information
The manufacturer accepts no liability for any consequences resulting from inappropriate,
negligent or incorrect installation or adjustment of the optional operating parameters of
the equipment or from mismatching the variable speed drive (Drive) with the motor.
The contents of this guide are believed to be correct at the time of printing. In the interests
of a commitment to a policy of continuous development and improvement, the
manufacturer reserves the right to change the specification of the product or its
performance, or the contents of this guide, without notice.
All rights reserved. No parts of this guide may be reproduced or transmitted in any form
or by any means, electrical or mechanical including photocopying, recording or by an
information storage or retrieval system, without permission in writing from the publisher.
Copyright © 9 September 2004 Control Techniques Drives Ltd

Issue Code: 4
Firmware: V03.00.02
1 Introduction ..................................................... 4
1.1 Who Should Read This Manual? .......................................... 4
1.2 Application Overview ............................................................. 4
1.3 Features ................................................................................ 5
2 Mechanical Installation ................................... 6

2.1 Application Module & Unidrive .............................................. 6
3 Electrical Installation ...................................... 8

3.1 Unidrive ................................................................................ 8
3.2 Unidrive Power / Motor Connections ..................................... 9
3.3 UTIM Signal Interface Unit .................................................... 9
3.4 Connector Location .............................................................. 9
3.5 Default Control Connections ............................................... 11
3.6 I/O Mappings ....................................................................... 15
3.7 Isolation and Suppression ................................................... 16
4 Software Installation ..................................... 17

5 Getting Started .............................................. 18
5.1 Unidrive ............................................................................... 18
5.2 Operating Modes ................................................................. 18
5.3 Scaling ................................................................................ 20
5.4 Resolution And Accuracy .................................................... 23
5.5 Commissioning Sequence .................................................. 24
5.6 Application Set-up Parameters ........................................... 32
6 Functional Description ................................ 38

6.1 Overview ............................................................................. 38
6.2 Jogging & Positioning .......................................................... 38
6.3 Homing / Datuming ............................................................. 39
6.4 Registration ......................................................................... 41
6.5 Flying Shear Profile Calculation .......................................... 44
6.6 Cam Control And Virtual Master Control ............................. 47
6.7 Gap Profile Generator ......................................................... 48
6.8 Tool Control ......................................................................... 50
6.9 Reference Selection and PID .............................................. 53
6.10 Hardware and Software Limits / Positions .......................... 56
6.11 Communications Watchdog ................................................ 60
6.12 Fault Handling ..................................................................... 60
6.13 Start / Stop Logic ................................................................. 62
6.14 Interlocks ............................................................................. 63
6.15 Batch and Master Control ................................................... 64
7 Parameter Descriptions ............................... 66

7.1 Relevant Unidrive Parameters ............................................ 66
8 Error Handling / Trouble Shooting .............. 97

8.1 Application Error Handling .................................................. 97
Winder Function Block Solutions Application Software User Guide for Use In Sypt Programming
Issue Number: 4 www.controltechniques.com
9 Advanced Features ..................................... 101
9.1 Serial Communications / Fieldbus Control ........................101
9.2 Software Version ...............................................................105
9.3 Mechanical Installation ......................................................105
9.4 Electrical Installation ..........................................................106
9.5 Unidrive set-up ..................................................................108
9.6 Operation Button Selection Actions ..................................109
9.7 Navigation ..........................................................................109
9.8 Operators Screens Description .........................................111
9.9 Access ...............................................................................118
9.10 Splash Screens .................................................................118
9.11 Parameter Save .................................................................119
9.12 Trip & Alarm indication ......................................................120
9.13 CTIU Function Keys Allocation ..........................................121
10 Quick Reference .......................................... 122

10.1 Application Parameters - Menu 18, Menu 19 and Menu 20 123
11 Documentation Reference .......................... 126

12 Signal Interface Unit .................................... 127
12.1 U.T.I.M. ..............................................................................127
12.2 U.T.I.M. 2 ...........................................................................130
Winder Function Block Solutions Application Software User Guide for Use In Sypt Programming
www.controltechniques.com Issue Number: 4
1 Introduction
1.1 Who Should Read This Manual?
This manual is intended to assist the engineer in commissioning the application
software, and should be read in conjunction with the documentation that is supplied with
the drive and other associated hardware. The safety systems that are required to
prevent risk of injury to persons operating or maintaining the machine are not discussed
in this manual. The engineer must be familiar with and able to implement the required
safety systems. This manual assumes that the engineer is familiar with relevant Control
Techniques products and understands the requirements for the application.
If you do not feel confident of the above, then you should contact your local Control
Techniques drive centre or distributor to obtain service / advice.
1.2 Application Overview
The Flying Shear is a common industrial application for cutting a product into smaller
lengths, without stopping the line, this means that the main production process is not
interrupted, and so machine productivity is maximised.
The cutting tool is typically mounted on a carriage that moves either parallel to the
product flow or at an angle across the product flow. The flying shear drive accelerates
the carriage to synchronise with the line speed, while synchronised the cut is done and
the carriage then decelerates and returns to its original position ready to cut again.
There are also many other similar applications where a carriage must be synchronised
at line speed and most of these can also be accommodated using the flying shear
application software.
The drive is configured using real engineering units of choice such as mm or inches.
This means that the configuration of the system is made very easy, through an operator
interface or by entering configuration parameters directly on the drive.
Flying Shear Solutions Software User Guide for Unidrive Classic 4

The forward profile is optimised for each application by breaking the synchronised, part
of the profile down into three areas: settling time, cut time and tool rise time, these are
entered in milliseconds. The drive will then calculate the profile and perform checks to
ensure that the parameters entered are achievable, given the length of motion available,
and also the required cut length.
Typical applications include various types of cut to length machines, depositors,
punches, product inspection, or any other process where synchronisation at line speed
is required.
A couple of possible applications are:
A machine extrudes plastic pipes that must be supplied to the customer in pre-cut
lengths. The extrusion process requires the extruder to run at a continuous speed to
maintain the quality of the product. The pipe is uniform along its length and provided the
length is within a set tolerance then the pipe is fit for sale. The flying shear is used to cut
the product cyclically.
The end product is a steel carton. In the first part of the process the steel is printed and
must then be punched using a registration mark printed on the product. The flying shear
is used to detect a mark and accurately synchronise the shear with reference to the
mark.
1.3 Features
• Hardware and software limits.
• Fieldbus interfaces are available: CT-Net, Profibus, Devicenet, Interbus-S, Modbus
plus, Can-Open and RS485.
• Manual functions are available such as Jogging.
• High-speed output can be used to fire the cutting tool.
• Registration can be used to initiate the cut.
• Batch counter.
• The motion profile may be changed during operation such as cut lengths,
acceleration etc.
• Real engineering units are used.
• Units are defined for the master and slave axis, as the number of encoder counts
per unit. The units are entered as a numerator and denominator to allow high-
resolution fractional values.
• Resolution of the cut-length may be entered to within 0.001 units.
• Profile optimisation reduces the machines mechanical stress: The return profile is
calculated to operate at the slowest speed and acceleration rate, and yet with
sufficient time to achieve the next cut, either triangular or trapezoidal profiles are
used.
• MMI support.
• Gap Control - a typical requirement for log cutting applications.
• Parallel or angled Shear.
• Registration, with or without windowing.
5 Flying Shear Solutions Software User Guide for Unidrive Classic

2 Mechanical Installation
NOTE Ensure the Unidrive is correctly installed in accordance to the Unidrive Installation
Manual
2.1 Application Module & Unidrive

• Isolate the Drive from the main supply and allow 5 minutes for the DC Bus
capacitors to discharge.
• Insert the UD70 Application Module as shown below. Ensure that it is correctly
inserted. The module will click firmly into place.
• The Unidrive must be disconnected from the mains supply before installing or
removing an option module.
2.1.1 Application Module

• To remove the module, pull on the black tab, and the module will disengage from
the connector and pull out of the Drive.
NOTE Ensure the Unidrive is correctly installed in accordance to the Unidrive Installation
Manual

2.1.2 Second encoder / resolver / SinCos Module
• The small option module connects to the Unidrive via a simple press fit connector.

3 Electrical Installation
3.1 Unidrive
3.1.1 Control
+24V digital supply (Terminal 22)
Supply for external digital signal devices.
Voltage Tolerance: ±10%
Nominal output current: 200mA
Overload output current: 240mA (including Digital Outputs)
Protection: Current fold-back above 240mA
+10V analog supply (Terminal 4)

Supply for external analog signal devices
Voltage Tolerance: ±1%
Nominal output current: 10mA
Protection: Current limit and thermal trip
Digital Outputs
Type of output: Negative logic digital (push-pull)
Voltage range: 0V to +24V
Max. output current: 200mA
Overload output current: 240mA (including +24V Supply)
Update Time: (info...) 5.5ms / 7.4ms
Digital Inputs
Type of input: * Negative logic digital
Voltage range: 0V to +24V
Absolute max. Voltage range: -3V to +30V
Input current when +24V applied: 3.2mA
Logic levels: Logic high: >+15VLogic low: < +5V
Sample Time: (info...) 5.5ms / 7.4ms
* Drives with firmware V2.10.4 and later allow the selection of either negative logic or
positive logic on the inputs. Selection is made with parameter 08.27.
Analog Outputs
Type of output: Single-ended analog - bipolar
Max. output voltage: -10V to +10V
Max. output current: 10mA peak
Load resistance: 1kΩ minimum
Protection: Short-circuit proof
Resolution: 10-bit plus sign
Update period: (info...) 5.5ms / 7.4ms

NOTE Whilst running the flying shear software, the only sample / update time available is
7.4ms, as the switching frequency is limited to 4.5kHz and 9kHz. See the Unidrive user
guide for further details.
3.2 Unidrive Power / Motor Connections

Please refer to the Unidrive documentation for the relevant information regarding:
• Voltage Rating
• Current rating
• Motor Connections
• Encoder / Resolver Connections
3.3 UTIM Signal Interface Unit

The U.T.I.M. (Universal Type-Interface Module) is a DIN rail mountable unit. It is
designed to help the user by providing conversion between standard signal levels.
Refer to section Signal Interface Unit on page 127 for more detail.
3.4 Connector Location

3.4.1 Unidrive Control Terminal Connections
1 11
21 31

3.4.2 UD70 Connections
Pin Function
1 0V serial comms
2 /TXD
3 /RXD
4 Digital Input 0
1 2 3 4 5
5 Digital Input 1
6 7 8 9 6 TXD
7 RXD
8 Digital Output
9 0V Digital
3.4.3 Small Option Module
40 55

3.4.4 Interface module
1 16
17 32
3.5 Default Control Connections

3.5.1 Control Connections
Unidrive Control Terminal
4 +10 Volts
Home Switch
7 AIN 2
22 24Volts
Run Command
26 F3
Drive Enable
30 Enable

3.5.2 Limit Switch Inputs
22 24Volts
Home Limit Switch
27 F4
Forward Limit Switch
28 F5
Reverse Limit Switch
29 F6
Reverse H/W Limit Switch
Forward H/W Limit Switch

Homing Switch
End of
Travel
NOTE If a failure to stop would cause a risk of injury to personnel, then a hardware safety
system should be used to ensure that the flying shear carriage would stop if the limits are
passed.
3.5.3 Hardwired Interface Connections

Shear Healthy Status Relay

2
24 F1
Shear Ready
K1
/ Running
31 0Volts
Master / Line Control
NOTE If you have chosen to use negative logic 8.27 = 0, then the shear ready relay above (K1)
needs to be connected between terminals 24 and 22.

3.5.4 Registration Sensor Connections
Wiring for Second Encoder Module - UD51 Only.
TTL Cable
TTL Cable Interface Module Length
Length
<=50M
<=1M (3ft)
UD51 Channel A (150ft)
54 22 24Volt 4
Freeze In Registration
21 3
0Volts Sensor
55
RS422
Terminate Screen
0Volts 51 0v at source
2 1
24Vdc 0V
Supply
NOTE For Sin Cos Encoders the Freeze input is connected to pins 48, 49 and 52, which are
Freeze, /Freeze and 0volts respectively.
NOTE Registration cannot be used if Resolver feedback is used as there is no Freeze input
available on the UD53 Resolver option module.
3.5.5 Tool Control Connections
TTL Cable TTL Cable

Length Length
Interface Module
UD70 <=1M (3ft) <=50M
Socket "D" (150ft)
Channel A
0 volts 9 17 24Volt 4
Tool Up
0Volts Sensor
TTL IN 0 4 18 3
TTL
Terminate Screen
Opto Isolated
at source
Channel B
19 24Volt 6
Tool Down
0Volts Sensor
TTL IN 1 5 20
TTL
5
Terminate Screen
Opto Isolated
at source
Channel C 24Vdc
TTL Out 8 8 24Volt 32

Tool
Actuator
Unidrive Control 7 31
TTL
Terminals
29
0Volts
F2 25 10
0Volts 31 9 A 10kohm shunt resistor is

2 1 required for this output when
driving a solid state load.
e.g. Digital input on another
device.
24Vdc 0V
Supply
This is not required for a
inductive load e.g. relay.

NOTE Tool up and down signal requirements are dependant on Cutter mode set in parameter
19.26. If the TTL input are used, then do not use parameters 19.46 and 19.48, both must
be set at 0 for correct operation.
3.5.6 Connecting to a remote device using RS485 Comms
1 2 3 4 5
CTIU
6 7 8 9
UD70
Socket "D" Remote Device
+Tx 6 +Rx
- Tx 2 -Rx
+Rx 7 +Tx
- Tx 3 -Tx
0v 1 Gnd
3.5.7 Monitoring
Unidrive Control Terminals
9 Analogue Out 1
10 Analogue Out 2
11 0 Volts
NOTE Analog output 1 and 2 are directed to parameters 3.02 (speed in rpm) and 4.02 (active
current) respectively, from default. The Analog outputs may be directed to other
parameters; refer to the Unidrive user guide for further details.

3.6 I/O Mappings
Setting parameter 18.44 to a 1 sets the default flying shear I/O mapping; 18.44 will
immediately return to 0 after it is set to1. Setting the normal Unidrive I/O mapping
parameters to alternative locations can change the default configuration. After a
default, the drive is set to positive logic, parameter 8.27 = 1.
Digital I/O
I/O Point Description Destination Invert In / Out Select

F1 Shear Ready 19.48 Off Out
F2 Tool Enable 19.49 Off Out
F3 Run Input 19.33 Off In
F4 Home Switch 18.32 Off In
F5 Fwd Limit 19.40 Off In
F6 Rev Limit 19.41 Off In
Analog I/O
Ain 1 / 3 are not used
Ain 2 is used to initiate a home sequence using programmable thresholds.
Hysterisis 1.0%
Threshold 50.0%
#19.38 Home Command
Ain 2 Input Value #07.02
Programmable Threshold Settings

12.03 = 7.02
12.04 = 50.0
12.05 = 1.0
12.07 = 19.38
NOTE If you do not want to initiate a homing sequence from analog input 2, then 12.07 should
be set to 0.00.

UD70 TTL I/O
The UD70 IO is used because the update is very fast (virtually immediate), and it
removes the need for additional external I/O, if you believe that your application does
not require the fast update then you could decide to use the normal Unidrive I/O.
TTL In 0 – Tool Clear / Up, or write 1 to parameter 19.46
TTL in 1 – Tool Down, or write 1 to parameter 19.47
TTL Out – Tool Cut Signal, same as parameter 18.43
NOTE Tool up and down signal requirements are dependant on Cutter mode set in parameter
19.26. If the TTL input are used, then do not use parameters 19.46 and 19.48, both must
be set at 0 for correct operation.
3.7 Isolation and Suppression

If the Digital inputs are to be switched from locations outside the control cabinet on long
cables, relays with a separate power supply should be used to isolate the drive from
harmful reflected or induced voltages.

4 Software Installation
There are two software files that are required to be installed within the Application
module, and these are as follows: -
1. Application file- Fly.bin
2. System file - This is dependant on the application and fieldbus interface used.
Version >= V03.00.02 should be used.
UD70OS.SYS - UD70 Application module only

UD70NET.SYS - UD70 and CTNet
IBSPROFI.SYS - UD70 and Profibus-DP or Interbus
DNET.SYS - UD70 and Devicenet
MBPLUS.SYS - UD70 and Modbus-Plus
DPLCAN.SYS - UD70 and CAN
CANOPEN.SYS - UD70 and CANopen
The following parameters indicate the installed software version. ‘0’ denotes no software
file is installed.
Parameter Description Parameter Notation

17.02 System file version number 3.06 = V03.00.06
20.49 Application file version number 10200 = V01.02.00
To download the system and/or the application file to the application module the
following items are required:
• A standard one to one serial cable connected between the PC serial port and the
RS232 port on the application module, (Connector C).
• Control Techniques WindowsTM ‘WinFlasher’ software. This software is on your
Flying Shear CD ROM together with the software files.

5 Getting Started
5.1 Unidrive
1. Default all drive parameters (refer to the Unidrive user guide).
2. Refer to the Unidrive Getting Started Manual to commission the Unidrive before
attempting to set up the Flying Shear Application.
3. If the UD70 is not new then check that the menu 20 parameters are zero, and erase
the old program using WinFlasher.
4. Set parameter 17.13 = 1, so that the application programmes will run automatically
on power-up.
NOTE Drive Switching Frequency is set at either 4.5 or 9Khz.

Position Loop Update = 1.84ms.
Speed loop update = 460us
5.2 Operating Modes

5.2.1 Parallel Flying Shear
With parallel flying shears, the carriage travels in the same direction as the material. In
the example shown below a shear is used to cut through a material, while the carriage
and the material are synchronised. The shear would then be raised and would return to
the start position ready to repeat the Cycle. The parallel mode is best suited to
applications where the tool operates instantaneously across the whole material width at
the same time, such as a punch tool or a shear.
PLC / CTIU
Return Motion
Cut Motion
Line Direction
NOTE The shear profile is calculated based on the maximum master speed, and at lower
master speeds than the maximum master velocity, the cut times 20.29, 20.30, 20.31
increase inversely proportional to the master speed e.g. with a maximum master velocity
(20.28) of 100 units / second and a cut time (20.30) of 100ms at a master speed of half
the maximum set in 20.28 the cut time will be 200ms or double. If your application
requires that the cut time is constant regardless of the line speed (e.g. a bag sealing
application), then parameter 18.50 can be set, which will keep the cut time 20.30 in real
time.

5.2.2 Angled Flying Shear
With Angled Flying shears the saw travels across the material at an angle to the product
flow, the speed that the saw carriage must travel depends upon the angle between the
shear and the material flow. This mode is especially useful in applications such as a
saw or a plasma-cutting tool where the tool must travel across the product at 90
degrees to the flow.
NOTE The Angled cut axis speed can be calculated from:

Angled cut axis speed = Line Speed / Cos θ

5.3 Scaling
A unit for scaling must be selected, such as mm or inches, any unit that represents
distance may be used provided the master encoder and the slave encoder use the
same. The scaling is entered as encoder edges per unit as an integer numerator and
denominator, parameters 18.13 and 18.12 for the master, and 18.15 and 18.14 for the
slave, respectively.
Distance is entered as units

Speed is entered as units / s
Acceleration is entered as units / s2
If a CTIU is to be used, parameter 18.11 selects which units are shown on the display.
0 = Undefined User units

1 = mm x 100
2 = mm x 10
3 = mm
4 = mm / 10
5 = mm / 100
6 = inches x 10
7 = inches
8 = inches / 10
9 = inches / 100
5.3.1 Selecting suitable units

The units selected affect the resolution and the maximum values of the parameters that
are entered, for example, if you were to use microns as your units, then the longest cut
length you would be able to set would be 32mm and the resolution would be 0.001
microns. Alternatively, if you used metres as your units then the cut length could be up
to 32000 metres.
Here are some examples of the parameters:
Parameter Description Resolution Maximum Value

(Units) (Units)
Cut Length 0.001 32000
Length of the shear travel 1 32000
Following error limit 0.001 32
Registration Position 0.001 32000
Fwd & Rev Software Limits 1 +/- 32000

5.3.2 Example Scaling Calculations
For this example we will select mm as our unit.
4096ppr encoder 2:1 Pulley
5000ppr encoder
1Rev of Screw = 20mm
E
100mm Diameter
Measuring Wheel
Master
The quadrature encoder will give the following resolution
4 * 5000 = 20000 counts / rev
Circumference of the measuring wheel is

PI * 100mm = 314.16 mm
The encoder counts per mm = 20000 / 314.16 = 63.66
The numerator and denominator could be entered as:

Numerator = 6366 - enter value into parameter 18.13
Denominator = 100 - enter value into parameter 18.12
In cases where the base units are a lot smaller than the longest cut length, the
resolution of the scaling will become more important to ensure cut accuracy is achieved,
(with the required tolerance): e.g. units in millimetres, cut length in 10’s of metres. In
these cases the numerator resolution is restricted by the parameter range of 32000,
therefore it is not advisable to use the base of 10 for the denominator, but to find the
lowest common multiples for both the Numerator (counts) and the denominator (units).
To check the scaling is correct perform the following:

1. Cut the longest length required
2. Measure the length cut
3. If the cut length is not to the length set (+/- tolerance), then change the master
scaling parameter/s as follows:
New scaling =
(18.13 / 18.12) x ((20.24 + 20.32) / Actual measured length)

Slave
The encoder resolution is 4 * 4096 = 16384 counts per revolution.
If the motor rotates 1 revolution, then the screw will travel 0.5 revs (2 :1 pulley), and the
carriage will travel 10 mm.
Encoder counts per mm = 16384 / 10 = 1638.4
The numerator and denominator could be entered as:

Numerator = 16384 - enter value into parameter 18.15
Denominator = 10 - enter value into parameter 18.14
If the value of the numerator is too large then the units must be changed, such as mm
multiplied by 10 could be used.
NOTE In this example, the ratio between the master and the slave resolution is approximately
a factor of 26 (1638.4 / 63.66), this means that during the time that the slave is
synchronised to the master, when the master moves 1 count then the slave must move
26 counts, this is like an amplifier with a very high gain, and can produce some problems
with noisy operation and instability. To prevent these problems, it is recommended to
increase the resolution of the master so that it is similar to the resolution of the slave, this
could be done by selecting a smaller measuring wheel diameter and / or increasing the
encoder resolution or using SinCos encoder (Refer to section SinCos Encoder
Application Notes).
Where it is not possible to fit a high resolution encoder, or if a system is retro-fitted re-
using an old encoder, parameter 18.35 has been introduced which enables a 40ms filter
which will help reduce motor noise caused by low resolution encoders. When the filter is
enabled there will be a small positional following error, when the master accelerates or
decelerates.
5.3.3 SinCos Encoder Application Notes

A SinCos encoder is a high-resolution feedback device, which can have the capability of
feeding the absolute position via a RS485 connection on power up. The encoder can be
supplied as single or multi-turn device. The Flying shear software does not
accommodate for the absolute position on power up, therefore a home routine is always
required to be performed.
Source Selection
The SinCos interface can be used as the Master or Slave (drive feedback also)
positional feedback, this is selected by parameter 16.14 (0 = slave : 1 = Master).
Resolution

The resolution as default is interpolated from 2048 * PPR to 16384, (14bit) counts per
revolution. This can be extend by setting parameter 71.19, (_Q19%) with the addition bit
resolution required, up to a maximum of 22bit (based on a 512ppr encoder).
Counts/rev = 214 + parameter 71.19
e.g. for 20bit resolution set parameter 71.19 = 6
NOTE Parameter 71.19 can only be accessed via serial communications, (e.g. Using CT
Browser, Sypt or CTIU).
To save and use the new resolution setting set parameter 17.19 = 1, (note this will
automatically reset to zero on acknowledgment).
Simulated Encoder Output

When the Master axis is driven by a Unidrive fitted with a SinCos encoder, the master
position can only be sourced to the slave by using the simulated encoder output on the
SinCos interface, (SinCos encoders cannot be daisy chained like a normal incremental
encoder). The simulated encoder output is equivalent to a quadrature encoder (not
SinCos), and the resolution is equivalent to the SinCos PPR (with no interpolation).
Therefore with a 512PPR SinCos encoder the simulated output would also be 512PPR
(2048counts per rev). Resulting in a much reduced & course resolution.
The SinCos encoder must be connected directly to the axis to benefit from the
resolution this encoder can provide.
Set up
For more information on the SinCos encoder interface set up refer to the SinCos User
Manual (0460-0085).
5.4 Resolution And Accuracy

Calculating the accuracy that is achievable from the flying shear depends upon many
factors, and so is very difficult to calculate reliably, however, from experience we can
make some assumptions and estimate the likely accuracy that we can realise.
If we assume that the mechanical system is well designed:

• The inertia mismatch between the load and motor is approximately 1:1.
• The couplings / gearing used are rigid and low backlash and not flexible rubber type
couplings.
• The motor / drive combination is capable of producing sufficient torque to accelerate
the load at the required rate.
We can say that typically on a system with a 4096-ppr encoder we can achieve a steady
state following error of between +/-10 – +/-50 counts per Metre travelled.
In the example in section 4.2.2 we can calculate 50 counts of the slave axis equates to
0.03mm/Metre, therefore the likely achievable accuracy of the positioning system is
worst-case +/-0.03mm/Metre. Other errors from mechanical tolerances will reduce the
achievable accuracy of the machine.

If the resolution is increased, such as by fitting SinCos encoders then the accuracy can
be improved, however it is not a linear relationship, if we double the encoder resolution
then we should not expect half the error.
If the ratio between master and slave is large then slight movements on the master axis
cause large changes in required position in the slave so the net effect is a greater
following error than if the gear ratio was nearer 1:1.
5.5 Commissioning Sequence
Enter Flying Shear Parameters.

Uncouple the motor from the machine and Check that the master and slave axes
place guards around the motor shaft to counts up in the forward direction, and
prevent injury to persons. that there are no errors shown in
parameter 19.22
Commission the drive for the motor, and

Run the Flying shear still uncoupled from
tune the speed & current loops.
the machine and with the virtual master.
Check that safety systems operate.
Refer to drive documentation.
Couple the motor to the machine and run

Select suitable units. the flying shear with a slow virtual master.
Reduce the current limit to reduce the risk
Refer to section 5.2.1 of damage to the machine, parameter
#4.07
Ensure that the tool is disabled. Disable

Check Inertia Mismatch the virtual master and run the real master,
(not more than X5) ensure that the flying shear is
synchronised to the master.
Check that I/O is operating for the cutter

Fill in the blank spaces in section 5.6 enable the cutting tool and run the flying
shear.

Commissioning Notes
Start
Leave the UD70 disconnected from drive.

Connect unidrive The Unidrive Manual will assist in
power. connecting the Unidrive and setting up
Set up the motor the motor map. Motor must be
map and perform uncoupled from the machine for practical
flux alignment test. and safety reasons.
Run the unidrive in keypad mode to

Test the drive to check satisfactory drive / motor operation.
ensure that the To use keypad mode set
motor runs 1.14 = 4 and apply the enable signal to
smoothly the drive (connect pin 30 and 31).
If UD70 is not supplied preloaded with

Insert UD70 and
software then use the software provided
load with the latest
on disk to load the software onto the
operating system
UD70 and CTIU operator interface if
and the .bin file for
used.
the flying shear.
Default IO mappings may be used,

Connect Unidrive however these will not be satisfactory for
control I/O and set every application, in which case configure
mappings for the IO mappings as required to perform
required functions the functions that you require. See the
Unidrive user guide for more information
on configuring the I/O.
Refer to Section 5.3 for guidance on

Select units and selection of suitable units
calculate the
scaling for the
master and slave

1 Commissioning Notes
Set Jog Speed, Accel and Decel. Refer to

section 6.2.
Set Jog
Parameters
18.28 -18.30
19.44 is used to change the slave forward

Jog the axis direction.
forward and check
that the direction is
correct, if not set
19.44
The easiest way to change the forward

direction of the master axis is to reverse
Run the master in the polarity of one of the quadrature
forward direction encoder inputs, reverse A and /A. Also
and check that the check that 18.10 shows a positive valuein
position counts up. the chosen forward direction. Failure to
do this, could mean that the cam profile
will run backwards i.e. 20.36 couning
down.
Set the Home

parameters Configure the mode of homing required.
18.19 - 18.25 Refer to section 6.3.
& 18.31
Configure Set up and test the operation of the

Hardware and hardware and software limits. Use the
Software Limits Jog function to check the hardware limits
19.14 - 19.15 before homing, and after homing to check
19.42 - 19.43 the software limits. Refer to section 6.10.

Configure the start Set the start position for the shear, this is
position of the relative to zeroposition after datuming.
shear.
20.39
Set the mode of the flying shear - Angled

or Parrallel.
Parallel Shear Angled Shear
What type of
shear ?
Set Mode.
Set 20.41 = 0 Set 20.41 = 1
Configure the flying shear profile. Note:

Configure Profile Configure Profile some of the parameters have two
20.23 - 20.35 20.23 - 20.35 meanings depending upon the selected
mode. Also check that 19.22 does not
contain an cam calculation error bit 4 = 1
(decimal 16). Refer to section 6.5.
Configure Gap if
Required In parallel shear mode a gap can be
inserted between the products, if this is
required configure parameters 19.23 -
19.25, and enable using 19.50. Refer to
section 6.7.

Commissioning Notes
3
Is Registration required for cutting the

product to a set length?
Registration is used in applications where

Registration the cut is required to be aligned to a mark
Registration? along the product. A sensor is used to
detect the mark. Refer to section 6.4.
Cyclic
4 Cyclic cutting is used when the product is

uniform along it's length without any
Set 20.23 = 0
distinguishing marks, such as in extruded
plastics. However in this mode a
registration sensor may still be used to
detect the initial edge of the product.
Dont Care Dwell In Cyclic mode only, we can decide the

First Cut?
position of the first cut.
Dont Care - In this mode the shear profile

Registration will begin as soon as the shear is in run
mode.
Registration - In this mode the shear will

begin one cut length after the edge of the
Set 19.30 = 0 Set 19.30 = 1 Set 19.30 = 2 product is detected. The registration sensor
is used to start the shear only.
Dwell - In this mode the shear will begin

after a dwell of one cut length. Providing
the edge of the product is aligned with the
start position of the shear the resulting cut
Configure the length will be right.
registration sensor
position.
20.42 - 20.43

Enable the Registration Mode by Setting

20.23 to 1.
Set 20.23 = 1
The application software must know the

Configure the position of the registration sensor,
registration sensor relative to the start position of the shear.
position. A positive value means that the sensor is
20.42 - 20.43 before the shear start position, a negative
value means that it is after.
Is windowing required? This is used

Yes No where there are several marks present on
Windowing? the product, and only one is required for
registration, the window excludes the
unwanted marks and picks up the
required marks. Refer to section 6.4.
Enable / Disable Windowing, for

Set 20.44 = 1 and windowing also need to set the window
configure Set 20.44 = 0 tollerance, and preset the master
20.45 - 20.47 position, to pick-up the correct mark, refer
to user guide for more information.Refer
to section 6.4.

Commissioning Notes
5
Set Position loop The position loop parameters must be

parameters and optimised to obtain the best performance.
Following error Refer to section 6.9.
Limits
The application software allows the user

to enable and disable trips and alarms,
Configure Error and also allows selection of the mode of
Handling trip, it is important to spend some time
Parameters. setting up these parameters to give the
19.18 - 19.22 required functionality and safe operation.
Configure the operation of the tool. Refer

Set the cutting to section 6.8.
mode
19.26 - 19.30
18.33
Configure comms The Comms watchdog is used to monitor

watchdog if the health of a comms link, it is important
required. to have this feature enabled when you
18.45 - 18.47 intend to control the axis from a remote
18.26 - 18.27 device. Refer to section 6.11
Configure Batch Batch control can be used to set the

Control If quantity of cuts required for a production
Required. run. Refer to section 6.12
18.16 - 18.18

Commissioning Notes
6
Check that the flying shear profile looks

Run the axis OK, and that the axis is stable. Refer to
decoupled and section 6.6.
with the virtual
master enabled
With the motor coupled to the machine

check that the flying shear profile is OK,
Couple the motor
always check that the hardware limits
to the machine and
operate, and stop the axis. You may also
run without product
wish to reduce the current imit (4.07)
and with virtual
temporarily at this point to prevent
master.
damage to the machine through incorrect
operation.
Run product and check that the tool

Disable Virtual
appears to be synchronised to the
master disable the
product.
tool , and check
that sychronisation
is OK
Use a scope to monitor the following

Re-tune the speed error, current and speed, tune to obtain
and position loop best performance.
PID Gains
Run product with tool enabled, and check

Enable tool and the operation
check the
operation
END

5.6 Application Set-up Parameters
1. Scaling Refer to section 5.3 or 7.2

NOTE scaling is only updated on power-up, Master Numerator 18.13
or by setting update scaling (parameter 18.37).
Master 18.12
Denominator
Slave Numerator 18.15
Slave Denominator 18.14
2. Jogging Refer to section 6.2 or 7.2
What speed do you want to Jog Units / s 18.28
Set the Jog Acceleration Rate Units/s/s 18.29
Set the Jog Deceleration Rate Units/s/s 18.30
3. Homing Refer to section 6.3 or 7.2
Is the home switch in the forward or reverse 1 = Forwards 18.22
direction 0 = Reverse
NOTE Forward direction is when the flying
shear travels in the same direction as the
normal flow of the product.
What Home mode is required 0 = Search for leading 18.20
edge of home switch.
1 = Search for leading
edge of Home switch
and then datum on the
next motor encoder
marker pulse.
What speed do you want to search for the Home Search Speed 18.19
home? Units/s
What speed do you want to back-off the home Home Back-off Speed 18.21
switch? Units/s
What Acceleration / Deceleration rates do you Homing Accel / Decel 18.23
want to use for homing Units/s/s
The homing sequence can fail if the time it Homing Time-out 18.24
takes exceeds a preset time. Time is ms
How long do you wish to make the time-out.
The position that you want to pre-set the Zero Position 18.25
position loop to at the home position. Units
What is the polarity of the home switch 1 = Normally Closed 18.31
0 = Normally Open

4. Registration Refer to section 6.4 or 7.2
How far is the registration input located from Registration Sensor 20.43
the flying shear start position? Position.
Units
Do you want to add a fine trim to the Registration Sensor 20.42
registration sensor position? Position fine offset.
Units/1000
Do you want to use windowing so that the Enable Windowing. 20.44
registration sensor excludes marks outside the 1 = Enable
window? 0 = Disable
The position will roll over to zero when the cut What Tolerance do you 20.45
length is reached, the window will be open want to apply to the
before and after the rollover within a tolerance. window?
Units
The master position may be preset to the value Master position preset. 20.47
of parameter 20.47 when a transition from 0 –
1 occurs in parameter 20.46.
5. Flying Shear Profile (Parallel) Refer to section 6.5, 6.10 and 7.2
Do you want the flying shear to synchronise to 1 = Cut on Mark 20.23
a mark on the product, or do you want the 0 = Run Cyclically
flying shear to run cyclically?
If cyclic mode is selected you can select when 0 = Cut Immediately 19.30
the first cut is executed. 1 = Cut Using the
registration sensor.
2 = Cut after one cut
length.
If cyclic mode is selected you can choose the 0 = Slow 20.40
mode of optimisation for the return section of 1 = Fast
the profile.
If fast is selected then the shear will return at
the maximum speed and dwell before the next
cycle.
If slow is selected the shear will return with
enough pace to achieve the next cut without
any need to dwell.
What is the start position for the flying shear? Units 20.39
What cut length do you want to achieve? Enter Cut Length In 20.24
Units
Do you want to add a fine adjustment to the Enter a Fine Offset To 20.32
cut length? The Cut Length.
Units / 1000

What is the travel available for the shear? This Units 20.25
is taken as the distance from the start position
of the flying shear to the hardware / software
forward limits.
What is the accel / decel rate for the shear Units/s/s 20.26
during the fly (forward) part of the profile.
during the return (reverse) part of the profile.
What is the Maximum Speed of the master axis Units/s 20.28
during this profile?
The synchronous part of the flying shear Settling Time 20.29
profile, is split into three areas, settling time, Milliseconds
the cut time and the tool rise time. Tool Down/Cut Time 20.30
If the cut time needs to be in real Milliseconds
Time at all speeds, set 18.50 to 1 (Refer to Tool Up Time 20.31
section 6.8.2). Milliseconds
The flying shear will only attempt to activate FE Cut Limit 20.33
the cut output if the following error (FE) is Encoder Counts
within the FE cut limit.
How do you want the flying shear to accelerate, 1 = S-Ramp 20.35
Linear or S-Ramped? 0 = Linear
NOTE The S-ramp profile should not be
used in conjunction with fieldbus options, as it
may cause the drive to spuriously trip.
At what rate would you like the flying shear to Set Fast Decel Rate 20.34
decelerate if a limit switch is hit. Units/s/s
5. Flying Shear Profile (Angled) Refer to section 6.5, 6.10 and 7.2
Enable angled shear = Parallel 20.41
1 = Angled
Do you want the flying shear to synchronise to 1 = Cut on Mark 20.23
a mark on the product, or do you want the 0 = Run Cyclically
flying shear to run cyclically?
If cyclic mode is selected you can select when 0 = Cut Immediately 19.30
the first cut is executed. 1 = Cut Using the
registration sensor to
detect the edge of the
material.
2 = Cut after one cut
length.

You can choose the mode of optimisation for 0 = Slow 20.40
the return section of the profile. 1 = Fast
If fast is selected then the shear will return at
the maximum speed and dwell before the next
cycle.
If slow is selected the shear will return with
enough pace to achieve the next cut without
any need to dwell.
What is the start position for the flying shear? Units 20.39
What cut length do you want to achieve? Enter Cut Length In 20.24
Units
Do you want to add a fine adjustment to the Enter a Fine Offset To 20.32
cut length? The Cut Length.
Units / 1000
What is the angle between the shear and the 0.01 degrees 20.25
material conveyor?
What length is the start distance? (not less Units 20.26
than 20.29)
during the return (reverse) part of the profile.
What is the Maximum Speed of the master axis Units/s 20.28
during this profile?
What distance is the shear to be accelerated Units 20.29
over?
What distance do you want the shear to be Units 20.30
synchronised for?
What distance do you want to decelerate the Units 20.31
shear in?
The flying shear will only attempt to activate FE Cut Limit 20.33
the cut output if the following error (FE) is Encoder Counts
within the FE cut limit.
How do you want the flying shear to accelerate, 1 = Sinusoidal Ramp 20.35
Linear or Sinusoidal Ramped? 0 = Linear
NOTE The S-ramp profile should not be
used in conjunction with fieldbus options, as it
may cause the drive to spuriously trip.
At what rate would you like the flying shear to Set Fast Decel Rate 20.34
decelerate if a limit switch is hit. Units/s/s

6. Virtual Master Refer to section 6.6 or 7.2
Enable Virtual Master. 1 = Enabled 20.37
0 = Disabled
Virtual Master Speed. Virtual Master Speed 20.38
Units/s
7. Tool Control Refer to section 6.8 or 7.2
Enable the tool cut output when synchronised. 1 = Enable 19.49
0 = Disabled
Tool manual cut. 1 = Cut 19.31
0 = No Cut
After the tool has synchronised then the tool up 1 = extend the 18.33
input (parameter 19.46) is checked to ensure synchronisation to the
that the flying shear is able to decelerate, if the master, and stop the
tool is not raised then we can handle the fault master.
in one of two ways: 0 = Decelerate as
normal.
Cutter Mode. Only modes 0 and 1 are available 0 = Set output during 19.26
in angled shear mode. the cut part of the cycle,
ignore tool up/down
signals
1 = Use tool up signal
2 = Use tool down signal
3 = use tool up and
down signals
Cut at start 0 = don’t cut on start 19.27
1 = cut on start
8. Position Loop Refer to section 6.9 or 7.2
Position Loop Velocity Feed Forward Gain Set to 1000 19.12 1000
Position Loop Proportional Gain Proportional Gain 19.13
Val / 1000
Position Loop Proportional Term Limit Set as a percentage of 19.16
the drive maximum
speed.
FE Limit, Following Error Maximum Value FE Limit 19.11
Before An Error Condition will Occur Encoder Counts
At Position Tolerance, this is the tolerance for Units/1000 19.17
the at position flag.
Change forward direction of the axis 0 = Normal 19.44
1 = Reverse

9. Hardware and Software Limits Refer to section 6.10 or 7.2
At what positions do you want to put the Forward Limit 19.14
software limits? Units
Reverse Limit 19.15
Units
What is the polarity of the Hardware Limits 1 = Normally Closed 19.42
0 = Normally Open
Do you want to disable the limit switches Enable Limits during 19.43
during homing; this will be needed if you use homing.
the limit switch as a homing switch, or if the 1 = Disable Limits
homing switch is outside the limit switch. 0 = Enable Limits
10. Watchdog Refer to section 6.11 or 7.2
Watchdog Enable 1 = Enable 18.45
0 = Disable
Watchdog In Error Delay, if the watchdog clock Watchdog Error Delay. 18.26
from the remote device does not change state Milliseconds
within the time allowed then an error state
would result.
Watchdog Out Time Period, This sets frequency Watchdog time period. 18.27
that the clock will change state. Milliseconds
11. Batch Control Refer to section 6.15 or 7.2
Enable Batch Control 1 = Enable 18.16
0 = Disable
Batch Quantity 18.17
Batch Reset 1 = Reset 18.38
Command Parameters
Update Scaling & Direction 0 – 1 Transition = Update 18.37 Not Mapped
Manual Tool Cut Command 0 – 1 Transition = Cut 19.26 Not Mapped
Drive / Software Reset 1 = Reset 19.32 Not Mapped
Shear Run Command 1 = Run 19.33 Mapped to F3
0 = Stop
Go to Start Position 1 = Go to Start 19.34 Not Mapped
Local / Remote Control 1 = Remote 19.35 Controlled by fieldbus
control word
Jog Forward 1 = Jog 19.36 Not Mapped
Jog Reverse 1 = Jog 19.37 Not Mapped
Home / Datum Command 0 - 1 Transition = Home 19.38 Mapped to Ain 2 through
thresholds
Abort Motion 1 = Abort 19.39 Not Mapped
Enable Tool 1 = Enabled 19.49 Not Mapped
Preset Master Position 1 = Preset 20.46 Not Mapped

6 Functional Description
6.1 Overview
The diagram below illustrates the software architecture.
Hardware & Software

Limits
Jogging & Positioning
Unidrive Digital Speed

Homing Position Control Loop
Reference
Registration Features
Cam
Flying Shear Profile

Generation
I/O Logic & Sequencing Comms Watchdog
Batch Control
Remote Device
6.2 Jogging & Positioning

Jogging can be done at any time provided the flying shear axis is idle and the tool is in
the up position. After Jogging, the axis can be sent back to the start position ready for a
flying shear profile. Hardware limits are always active when jogging; the software limits
are also active providing the system has been homed.
NOTE The Jog command is a rising edge triggered. If Jog forward and Jog reverse are selected
at the same time, the first one detected takes priority.
Jog Speed 18.28 19.07/0 Jogging

Jog Acceleration 18.29 19.07/1 Traversing to Start Position
Jog Deceleration 18.30 Jogging / 19.07/2 At Start Position
Start Position 20.39 Positioning
At Position Tollerance 19.17 Control &
Position Profile
Generation
Jogging Position Reference To PID >>
Jog Forward 19.36

Jog Reverse 19.37 Sequencing
Traverse to the start Position 19.34

6.3 Homing / Datuming
To perform a home the shear
• Must not be in another mode e.g. Jogging, cutting.
• The drive must be healthy and enabled
• The Tool must be in the up position
• Sequence Abort (19.39) must not be active
During Homing:
Homing Switch
Start Position
1.
The flying shear carriage travels at home speed to find the home switch.
Homing Switch
Start Position
2.
The flying shear reverses at back-off speed, a percentage of the home speed (18.19),
until the home switch is reset, or finds the next marker pulse; the position is then pre-set
to the zero position preset (18.25).
Homing Switch
Start Position
3.
The carriage travels to the start position, ready to run.

NOTE If you select a low home acceleration / deceleration rate (18.23), with a high home speed
(18.19), during homing the shear may overshoot the home switch and crash the carriage.
This is most likely to cause damage if 19.43 is set disabling the limit switches whilst a
home sequence is completed. The lower the home back-off speed, the more accurate
the homing routine will be.
Homing Timing Diagram
18.20 = 0
18.20 = 1
Slave Velocity
Home Switch
Marker Pulse
18.01 when 2 3
18.20 = 0
18.01 when
2 3
18.20 = 1
Home Switch Input 18.32 18.01 Home Status

Home Switch Polarity 18.31 18.02 Home Done Flag
Home Speed 18.19 19.07/3 Homing Sequence Active
Homing
Home Mode 18.20 19.07/4 Homing Sequence Done
Control &
Home Backoff Speed 18.21 19.22/7 Homing Sequence Fault
Home Direction 18.22
Position Profile
Home Accel and Decel 18.23
Generation
Home Time Out (ms x 10) 18.24
Home Datum Preset 18.25 Homing Position Reference To PID >>
Home Command 19.38 Sequencing

6.4 Registration
The registration sensor can have different functions depending upon the mode of the
flying shear, cyclic or Registration.
In cyclic mode the flying shear can be used to detect the initial product edge and allow
the first cut to be as accurate as the following cuts, setting the first cut mode to 1 (19.30)
enables this function.
In Registration mode the registration sensor is used to set the position where the flying
shear will synchronise with the master. The sensor could be used to detect the position
of a mark on a printed product, or alternatively to detect individual products that are
randomly spaced out.
The position of the registration sensor is important. Once a registration event has
occurred there must be enough space for the shear to accelerate, and synchronise, but
if the sensor is located some distance from the shear some loss of accuracy may result.
Material flow
Distance between registration sensor and tool

start position 20.43
Material flow
Shear start
position
Distance between registration sensor and where

the tool meets the edge of the material 20.43

The registration offset between the registration sensor, and the knife start position are
entered into the registration offset (20.43) and fine offset (20.42), and allow a resolution
of up to 0.001 units. If this is entered accurately then the flying shear will synchronise
with the position where the registration sensor detected the registration event.
However, this is not always desirable, it may that you wish to detect a mark, but
synchronise a fixed distance from that position, this can be achieved simply by adding
or subtracting from the distance between the sensor and the knife start position, though,
there must still be enough distance for the flying shear to accelerate and synchronise
with the new position.
Windowing
The registration sensor may detect several marks during each cycle, however, it is
common that only one of the marks is relevant for registration purposes, in this case we
can enable windowing, which will reject marks that are detected outside a small position
window. The cut length (20.24) is used to set the rollover distance relative to the master
position count. The window tolerance (20.45) is then used to set how wide the band is
where the master will accept a registration mark. As shown in the diagram below, the
window is always located about the rollover position. When a valid registration mark is
detected, the position of the master is then automatically reset to zero, so that any drift
in position will be compensated.
Master Position
Cut Length
Window Open
Window Open
Window Open
Zero Position Window Open
To start the flying shear using the correct mark, the master should be jogged so that the
mark is aligned with the registration sensor (it can be just before or on the registration
mark), and the master position is then reset to zero by toggling 20.46. When the flying
shear is then started, it will cut in the correct position. If it is necessary to configure the
window whilst running, 20.46 should be toggled before the required mark and not on it,
as you may create a scrap cut.
If the sensor is located further from the start position than one cut length, then there will
be several registration positions that need to be recorded. Up to 25 registration events
can be buffered at any time.

43
Distance To
Registration Sensor 20.42 Val /
Fine (units /1000) 1000
+
Distance to
Registration Sensor 20.43 19.10 Master Position
(units)
Windowing Enable 20.44
Cut Length 20.24 Trigger Cam To CAM >>

20.32
Registration
Cut Length Fine
Registration Windowing Tollerance 20.45
Preset Master Position Command 20.46
Preset Master Position Value 20.47
Issue Number: 4
Flying Shear Solutions Software User Guide for Unidrive Classic
6.5 Flying Shear Profile Calculation
The profile is calculated automatically from parameter data that is entered in real
engineering units. The profile is checked to ensure that it can be achieved without
exceeding any of the entered parameters, such as shear length. If there is a problem
with the entered profile, a cam calculation error will be flagged in the raw alarm word
(19.22) bit 4, and the cam status word (20.22) will show the type of error.
From the data a CAM profile is generated with 10 points, as shown below. Not all of the
points are always used, such as, we are able to use either a triangular or trapezoidal
return profile, whichever is the most efficient, and so while the standard profile has a
segment 8, this may or may not be required.
The cam can be recalculated while the flying shear is running. The new cam will be
calculated, and will take effect on the following flying shear cycle, providing the cut-
length &/or profile information is loaded before point 9 of the current profile. . The
current cam / profile point, is displayed by the cam pointer (20.36).
If the new calculated cam has an error, then the cam will not be accepted, and will
generate a fault in the fault word (19.22). This can be used to generate an alarm or a trip
as required.
The maximum speed for the return profile is determined by parameter 1.06 x 0.99.
Normally there is no need adjust any of the profile parameters whilst the shear is
running, however if parameters are changed incrementally via the Unidrive SP keypad
whilst the shear is running, it will take 2 profile cycles before the new values are
accepted.
Forexample, If the current cut length is 1500mm and you decrement the value in steps
of 100 to a new cut length of 1000mm using the keypad, the next cut length will be
1400mm as the cam recalculation instantly grabs the first value it sees, after which it will
use 1000mm.
If comms are used to change a profile parameter (e.g. CTIU) whilst the shear is running,
the current profile run will be completed, after which the new measurement will be used.
N.B. for this to be true the new value has to be entered before the cam pointer, 20.36,
reaches 9.
NOTE The first time the flying shear is run, if there is a cam calculation error, You will not be
able to start the shear. Check if 19.22 and 19.18 bit 4 is 1 if it is, modify the profile
parameters to rectify the fault, and reset the shear (Toggle 19.32).
NOTE If a small cut length can not be achieved because the required cut length (20.24) is
smaller than the minimum cut length (20.21), try making the maximum master velocity
(20.28) as close as possible to the actual master velocity. If this does not reduce (20.21)
sufficiently; for a parallel shear, increase the fly acceleration / deceleration rate (20.26),
and for both parallel and angled, increase the return acceleration / deceleration rate
(20.27). The acceleration and deceleration rates should only be increased within the
limits of the machine, drive and motor.

Parallel Shear Profile
Vs Regis-
Accel. Settling Cut Tool up Abort Accel. Accel. Accel. Cyclic
tration Rate Time Time Time Time Rate Rate Rate Dwell
Dwell 20.26 20.29 20.30 20.31 20.26 20.27 20.27
Max Line
speed
20.28
20.40= 0
Max Drive
Speed 20.40= 1
01.06 x 0.99
0 1 2 3 4 5 6 7 8 9 10
Profile Construction
Angled Shear Profile
Vs Regis- Accel.
Decel. Accel. Accel. Cyclic
tration Distance
Dwell 20.29 Synch. Distance 20.30 Distance Rate Rate Dwell
20.31 20.27 20.27
Max Line
speed
20.28
20.40= 0
Max Drive
Speed 20.40= 1
01.06 x 0.99
0 1 2 3 4 5 6 7 8 9 10
Profile Construction

Issue Number: 4
Calculation Control Word 20.23 20.22 Cam Calculation Error
Desired Cut Length 20.24 20.21 Minimum Achievable Cut Length
Shear Length 20.25 19.07/6 Cyclic Fly Selected
Fly Profile Accel / Decel Rate 20.26 19.07/8 Registration Mode Selected
Cam is Currently Being Calculated /
Return Profile Accel / Decel Rate 20.27 19.07/9
Flying Shear Loaded
Maximum Master 20.28 19.07/10 Cam Is Initialised
Velocity Profile Cam Calculation
Settling Time (ms) 20.29 19.22/4
Calculation Parameter Fault
Cutting Time (ms) 20.30
Tool Clear Time (ms) 20.31
Cut Length Fine Adjustment (Units / 20.32
1000)

Tool width (Units / 1000) 20.20
Ramp Mode ( 0=Linear, 1 = S) 20.35
Cam Array To CAM >>
Sequencing
46
6.6 Cam Control And Virtual Master Control
The Cam accepts inputs from the registration block and the profile calculator, and
executes the cam with reference to the master position.
For commissioning purposes a virtual master may be used to check the system without
the need to waste product, the virtual master does not have a ramp, and so the speed
should not be changed by large increments while the profile is in operation.
Control >>
To Tool
Running
Cam
19.07/5
CAM Reference
Position
Pointer
20.36
Cam
Sequencing
CAM
Virtual Master
Select
20.37
Master
Virtual
19.33
19.10
Trigger Cam
Cam Arrays
Master Position
Flying Shear Run Command
Virtual
Master
20.38
Speed
From Register
From profile
Calcs >>
>>

6.7 Gap Profile Generator
Some applications require a gap to be inserted between products by accelerating above
synchronisation speed once the cut has been done, using the tool to push the cut
material forward (Parallel shear only). This is also useful where the product is viscous,
and so requires the product to be completely severed during the cut.
The gap is achieved using a trapezoidal profile generator which is added on to the main
position reference to produce the gap, it is important to note that the gap profile is
triggered by the tool down signal, or in applications where tool down is not used then it
is triggered when the Cam is in tool-up part of the cycle (Cam point 4). The Gap profile
is not synchronised to the master like a Cam and so once triggered will continue even if
the master is stationary.
NOTE If the shear is in Tool Cut mode 1 (19.26 =1), and Tool Up Time (20.31) is set to low, the
gap profile may not have enough time to execute, so the Tool Up time must be increased.
Cam Profile
Gap Profile
Output profile
NOTE The overall speed of the Profile and Gap must not exceed the slave motor linear speed
detailed below:
Pr1.06 × 0.99 × Pr3.21 × 4 × Pr8.14
Max Slave Linear Speed = ---------------------------------------------------------------------------------------------- Units/s
Pr8.15 × 60

49
Gap Enable 19.50
Gap Length 19.23
Gap Accel / Decel 19.24 Gap Linear
Gap Relative Speed 19.25 Position Profile
Generator
Gap Position Reference To PID >>

6.8 Tool Control
For many applications the tool requires very accurate control to ensure that the flying
shear profile is optimised to achieve the smallest cut length at the highest line speed.
By setting the time required for performing the cut and using a high-speed output direct
from the UD70 to activate the cut mechanism we can optimise the performance of the
shear. The UD70 output is a TTL active low output, which requires buffering to give a
usable 24volt output. To provide a fail safe system an enable signal is required to
prevent the knife being activated unexpectedly if the TTL signal is lost.
TTL Tool Cut Signal

Tool Cut Signal
24Volt Tool Enable
Settling Time
Abort Time
Cut Time
Flying Shear
Up Time
Profile
Tool Enable
TTL Tool Cut
Tool Cut Output
NOTE The enable signal is generated through software and therefore cannot be relied upon to
prevent injury to persons working on or around the machine. It is mandatory for a
hardware safety circuit to be implemented to electrically isolate the moving parts to
provide a safe environment.

6.8.1 Cutter Modes
The cut mode (19.26) allows the user to select one of four cutter modes:
Mode 0
The cut output is switched on during the cut segment of the flying shear, and off at any
other time. The tool up / down inputs are not used, and so the system will not detect
that the tool is jammed in the product.
Mode 1
The cut output is switched on during the cut segment of the flying shear, and off at any
other time. The tool up signal is used to detect that the tool is up at the end of the
synchronised period, this can be used to synchronise the shear with the master for an
extended period, and initiate a line stop, or alternatively can be used to flag an error or
trip the drive (see Tool Sync Enable (18.33)). In this mode if the Tool Up signal is not
present before shear run is enabled (19.33 = 1), then the shear will not run.
Mode 2
The cut output is switched on at the start of the cut segment of the flying shear, and off
as soon as the tool down signal is received. If by the end of the flying shear cut segment
the tool down signal has not received, then the tool output is switched off anyway and
an error condition is set, which can be used to alarm or trip the drive . If the Tool down
signal is still on at profile segment 5, then the drive will behave the same as if a tool up
signal is not received, i.e. depending on how Tool Sync Enable is set. This mode is not
available when Angled shear is selected.
Mode 3
This is the same as Mode 1 and mode 2 together. This mode is not available when
Angled shear is selected. In this mode if the Tool Up signal is not present before the
shear run is enabled (19.33 = 1), then the shear will not run.
6.8.2 Real Time Cut

When real time cut is enabled (18.50=1), the tool cut time (20.30) is set in real time, in
milliseconds, and is not influenced by the line speed. The tool is fired at the beginning of
profile point 3 (see shear profile diagram, section 6.5).
When real time cut is disabled (18.50=0), the tool cut time (20.30) is only applicable
when the line is running at the maximum master velocity (20.28). The cut time will
increase inversely proportional with line speed e.g. If the maximum master velocity
(20.28) = 100 Units / s and the cut time (20.30) = 100ms, at maximum line speed the cut
time is 100ms, and at half maximum line speed the cut time is 200ms.
6.8.3 Start Cut Mode

If start cut is set (19.27=1), then the flying shear will always perform an initial cut when
shear run is enabled (19.33 = 1), this is so that any scrap can be removed, and can be
used to ensure that the first cut is of the correct length.

Issue Number: 4
>> From CAM
CAM Reference CAM Position To PID
Reference >>
Syncronise
Position
Reference
Cam
Position
Pointer Tool Cut Output
Cutting Mode Mode 19.26 18.43
Cut on start enable 19.27 TTL O/P
Tool Sync on Fault 18.33 Tool Enable Output

Tool Up Signal (TTL) TTL In 0 TOOL 18.42
Tool Up Signal (Non TTL) 19.46 CONTROL
Length of the last cut
Tool Down Signal (TTL) TTL In 1 18.08
Tool Down Signal (Non TTL) 19.47 Length of the cut befor the last cut
Enable Tool Output 19.49
18.09
Following Error Cut Limit 20.33
Real Time Cut Enable 18.50
52
6.9 Reference Selection and PID
The reference is selected automatically by the sequencing.
>> From 19.01

Jogging Position Reference
Jogging
>> From PID Position Reference To PID >>

Homing Position Reference
Homing
>> From
Cam Position Refence +
Cam +
>> From
Gap Position Refence
Gap
Sequencing
The position loop encompasses a Proportional (P) and Velocity Feed Forward (VFF)
terms, in dynamic position loops such as flying shears integral and differential gains do
not offer any benefits. The VFF gain is calculated so that it will produce the correct
values if the gain is set to 1000, any other value will give a steady state error. The
proportional gain will require tuning to achieve the best response for the mechanical
system.
6.9.1 Tuning Procedure

1. Tune the speed and current loop gains to the required profile acceleration rates and
cycles. Use the profile for the shortest cut at the maximum allowable line speed.
Current Loop Parameters: Proportional Gain 4.13
Integral Gain 4.14
Speed Loop Parameters: Proportional Gain 3.10
Integral Gain 3.11
Differential Gain 3.12
Refer to Unidrive documentation for further information and/or use Unisoft gain
calculator wizard to determine the optimum gains.
2. Tune the position Loop.

a. Velocity feed-forward gain - this derives the rate of change of position
reference. This is set in fixed-point integer where 1000 = 1.000.
i. Set to 1000, if the motor encoder is used.
ii. Set to the gearbox ratio multiplied by 1000, if the auxiliary
encoder is used.
With the proportional gain set to 0 and the velocity feed-forward gain set correct, this
can be used to tune the speed loop gains as it provides the required speed profile
reference generated from the CAM, with no positional correction from the proportional
term.

NOTE Without a Proportional term, an accumulative position error will occur, so care must be
taken if this method of tuning of the speed loops is used as the end limits may be
exceeded.
b. Proportional gain - this provides the amount of position correction from the
position error. This is set in fixed-point integer where 1000 = 1.000. For an
error of 1 encoder count and a proportional gain of 1000, there will be an
output of 1 count per second.
c. Proportional Output Limit - the proportional output is summed with the velocity
feed-forward output, the amount of proportional output correction applied to
the velocity feed-forward is limited by parameter 19.16, nominally this set
between 1 and 20%, dependant on the application. If set too low a following
error will accumulate and will effect the deceleration or end of the profile, and
may also trip the drive on Tr81.
To help tune the system a scope should be used connected to analog outputs 1 & 2.
Analogue O/P 1 9
Analogue O/P 2 10
0 Volts 11
Unidrive
Analog output 1 can be set to give following error and analog output 2 set to give the
speed profile of the flying shear.
The speed and current can be sourced to the analog on a fast update by setting
parameter 07.30 = 1, (refer to user manual). The following error analog update will be
slower, max 8ms).

55
Velocity feed forward Gain
d
dt 19.12
Proportional Gain Speed Reference

Position Error +
>> From Ref
PID Position Reference + 19.13 + 01.21
Selection -
19.06 Position Error (Enc Counts)

Proportional Output Limit
19.02 19.16
19.05 Position Error (Units x 1000) (Percentage of max speed)
Position Feedback
19.03 19.22/1
FE Limit (Encoder Counts) 19.11
Issue Number: 4
6.10 Hardware and Software Limits / Positions
NOTE A risk assessment should be carried out to determine the potential risk of injury to
persons caused by the flying shear drive loosing control, if any risk exists then the
standard hardware and software limits are not suitable. An external safety circuit should
be used that utilises built-in redundancy to detect a potential hazard and automatically
mechanically brake the flying shear safely.
The Hardware and software limits will override any other flying shear functions, and will
initiate a flying shear deceleration. This is controlled by fast ramp enable (18.48); if
18.48 = 0 then the shear will stop instantaneously / Shear pin, if 18.48 = 1 then the
shear will stop at the fast decel rate (20.34). It will also cause an alarm in parameter
19.22, this may be used to trip the drive, or cause an alarm.
Reverse hardware limit switch Forward hardware limit switch
Zero position Forward software limit
Reverse software limit Shear length
Homing switch
Shear start position
18.25
19.15
20.39
20.25
19.14
Example setup 1:
18.25 = 200 Units
19.15 = 100 Units
20.39 = 500 Units
20.25 = 500 Units
19.14 = 1050 Units

Reverse hardware limit switch Forward hardware limit switch
Zero position Homing switch
Reverse software limit Forward software limit
Shear length
18.25
19.15
20.39
20.25
19.14
Example setup 2:
18.25 = 1000 Units
19.15 = 100 Units
20.39 = 300 Units
20.25 = 500 Units
19.14 = 900 Units
s
Reverse hardware limit switch / Homing switch Forward hardware limit switch
Zero position 18.25 = 0 Forward software limit
Reverse software limit Shear length
19.15
20.39
20.25
19.14

Example setup 3:
18.25 = 0 Units
19.15 = 200 Units
20.39 = 400 Units
20.25 = 600 Units
19.14 = 1050 Units
Reverse limit switch
Zero position
Reverse software limit
Ma
ter Homing switch
ial
flo w
Shear start position Forward limit switch
Forward software limit
θ = 20.25
18.25
19.15
20.39
20.29
20.26
Min
20.30
19.14
Example setup 4:
18.25 = 170 Units
19.15 = 90 Units
20.39 = 400 Units
20.25 = 3000 = 30.00 Degrees
20.29 = 110 Units
20.26 = 200 Units
20.30 = 500 Units
19.14 = 1150 Units

6.10.1 Hardware Limits
Disable Limits During Homing

19.43
Homing in Progress 18.48
H/W Limit Polarity Select 19.42
Fwd H/W Limit 19.40 19.22/8
Rev H/W Limit 19.41 19.22/9
6.10.2 Software Limits
System Homed Flag 18.02

18.48
Fwd S/W Limit 19.14

19.22/10
Current
19.01
Position
19.22/11
Rev S/W Limit 19.15
NOTE The software limits are only active after the homing sequence has been completed.

6.11 Communications Watchdog
The Watchdog is used to provide a mechanism to ensure safe operation when
movement is being controlled from a remote device. The watchdog checks that the
remote device is online and capable of both sending and receiving data. This is done by
sending a clock signal to the remote device, which responds by resending the same
clock signal back, the returned signal is then monitored to make sure that the received
data is of similar clock period to the sent data.
Remote
Watchdog
18.45 18.47
Device
Enable
Watchdog
18.46
Trip Delay 18.26
Generator &
Monitoring
Output period 18.27
Watchdog Fault
19.22/15
6.12 Fault Handling

The Flying Shear fault handling scheme, may be monitored and adjusted with the
following parameters:
Parameter 19.18 is the Alarm word. This is a 14 bit word which indicates the status of
the alarms; a bit at 1 indicates an alarm is active e.g. if bit 4 is 1 then there is a cam
calculation alarm. See list below for individual bit functions.
Parameter 19.19 is the Alarm / Trip mask word. This is a 14 bit word which selects
whether an alarm should trip the drive; a bit at 1 indicates that particular alarm is active,
and will trip the drive e.g. if bit 4 is 1 then if there is a cam calculation alarm the drive will
trip. See list below for individual bit functions.
Parameter 19.20 is the Trip conditional select word. This is a 14 bit word which selects
when the drive should trip under fault conditions; a bit at 1 indicates that a trip will occur
immediately, a bit at 0 indicates that the drive will trip on that particular fault at the end of
the current profile cycle e.g. if bit 4 is 1 then the drive will trip immediately if a cam
calculation fault occurs. See list below for individual bit functions.
Parameter 19.21 is the Alarm / Trip Enable mask. This is a 14 bit word which enables
whether a fault should trigger an alarm or drive trip. A bit at 1 indicates an Alarm / Trip is
active, a bit at 0 indicates an Alarm / Trip is inactive e.g. if bit 4 is 1 then a cam
calculation fault is enabled to trigger an Alarm or Trip. See list below for individual bit
functions.
Parameter 19.22 is the Raw Alarm Word. This is a 14 bit word which is used to generate
the above parameters; a bit at 1 indicates a fault is active e.g. if bit 4 is 1 then there is a
cam calculation fault. See list below for individual bit functions.

Bit functions
Bit 0 - Tool did not rise at the end of the cycle – alarm only
Bit 1 - Following Error Outside Limit
Bit 2 - Other tool error
Bit 3 - Start-up cut not done as master not stationary
Bit 4 - Cam calculation parameter fault
Bit 5 - Master Speed too fast
Bit 6 - Sequence abort parameter fault
Bit 7 - Homing Fault
Bit 8 - Fwd H/W Lim
Bit 9 - Rev H/W Lim
Bit 10 - Fwd S/W Lim
Bit 11 - Rev S/W Lim
Bit 12 - Remote Fieldbus Trip
Bit 13 - Watchdog fault error
When these parameters, 19.18 to 19.22, are viewed from the drives display, the decimal
equivalent will be shown e.g. bit 4 will be shown as 16 (24).
To reset an Alarm / Trip, first remove the cause of the trip, then toggle 19.32 (0 – 1 – 0).
Parameter 19.32 performs an application reset together with a drive reset.
NOTE Pressing the red reset button on the drive will only reset drive trips, it will not perform an
application reset e.g. If a hardware or software limit has been reached, you will be able
jog off the limit and re-home the system, but until the alarm has been reset (19.32 = 1),
you will not be able to start the shear.

6.13 Start / Stop Logic
Start / Stop logic flow diagram
Start
Master and shear are

stopped
Start shear
Shear will sit in the run

state waiting for the
master to move
No Press stop
Run Master? or set 19.33
to 0?
Yes
The profile sequence will

Shear will run the be aborted, and the
programmed profile shear will sit in the Stop
state
Press stop No Stop the master

End
or set 19.33
during the profile?
to 0?
Yes
The current profile

sequence will be finshed, Press stop
and the shear will then sit or set 19.33
in the Stop state, at the to 0?
Start position.
No The cam pointer

Is cam pointer at
is not at position
position 3 or 4?
3 or 4?
Yes
Shear will stay in the run

state, and will complete
The shear will go into the
the profile run once the
Stop state
master is started, and
then stop
End When the shear is

started, it will move to the
start position. This will
create a waste cut
Yes No Press stop

Start master? or set 19.33
to 0?

6.14 Interlocks
The flying shear software contains several interlocks to prevent damage occurring to the
tool. If you are trying to perform a Jog, Home, Go To Start or Run, and you can not: the
following lists detail the interlocks which need to be true before the action can be
performed.
Jog Interlocks
Drive must be enabled and healthy (18.49 = 1)
A flying shear profile must not be running (19.33 = 0)
The shear must not be homing (19.38 = 0)
A Go To Start must not be in progress (19.34 = 0)
A Sequence Abort must not be selected (19.34 = 0)
A manual cut must not be selected (19.31 = 0)
If tool control mode 19.26 is at 1 or 3 then the tool must be up
Home Interlocks
The shear must not be Jogging (19.36 = 0 and 19.37 = 0)
There must not be a homing fault (18.01 = a negative value)
Go To Start Position Interlocks

The shear must not be on a software / hardware limit (check 19.22)
The shear must be homed (19.07 bit 4 = 1)
Run Interlocks
The shear must not be on a software / hardware limit (check 19.22)
The shear must be homed (19.07 bit 4 = 1)

6.15 Batch and Master Control
6.15.1 Batch control
The flying shear software incorporates a batch counter, with the following functions:
Batch Enable (18.16):

This enables batch control when set to 1
Batch Quantity (18.17):

This sets the number of cuts in a batch, from 1 to 32767.
Batch Reset (18.38):

This resets the batch counters, both up (18.04) and down (18.05), and also resets
the Batch flags, Last Cut (18.41) and Batch done (18.06). Batch reset must be
toggled (18.38= 0 – 1 – 0) to fully reset, and re-enable the batch counter; if the batch
reset is just set from 0 to 1 the flags and counters will all be reset, but the batch
counter will not function until batch reset is set back to 0. After a batch has been
completed, the shear will stop at the start position; toggling the run command (19.33
= 1 – 0 – 1), will reset the batch counters and flags.
Batch Count Up (18.04) and Down (18.05):

These count the number of cuts performed. The count is triggered by the Tool Cut
Output. If Tool Enable (19.49) is not enabled (19.49=1), then the Tool Cut Output will
not be triggered, and therefore the batch counter will not function.
6.15.2 Master Control

The flying shear drive is able to interlock with the master drive, and provide control
signals. Three control signals are given: System Healthy, Run Command and Last
Cut:.
System Healthy
If the system healthy is false then there is a serious problem, the master drive
should decelerate at the maximum safe rate to ensure a minimum of damage.
Connecting this interlock is highly recommended.
Run
The Run signal may be used to command the master drive to run and stop, or may
be used as a flying shear ready interlock. This signal is optional.
Last Cut
The last cut signal is used to indicate that the current cut will be the last, this can be
used to reduce the speed of the master to a crawl until the run signal is removed,
this will result in a minimum of waste production. Last cut stays on until it is reset
(18.38 = 1), or until a new batch is started. This signal is optional.

System Healthy
Batch Enable 18.16 18.49
Batch Quantity 18.17 Run

19.48 Master Drive
Batch Reset 18.38
Master and Last Cut (Optional)
Master Run OP Enable 19.45 batch 18.41
Tool Enable 19.49

control
Sequencing
18.04 Quantity of Batch Completed

18.05 Quantity of Batch Remaining
18.06 Batch Done
NOTE 19.49 tool control enable must be set to 1 for the batch counter to function.

7 Parameter Descriptions
7.1 Relevant Unidrive Parameters
7.1.1 Parameters set by software on power-up
17.11 Clock Task Tick Time

Application Setting 10 – 10ms
17.12 Position Loop Enable

Application Setting 12 – Run Pos loop 1.84ms time base
17.13 Application Auto Run

Application Setting 1 – Auto Run
17.14 Enable Global Trips

Application Setting 1 – Global trips enabled
17.17 Trip If Parameter Write Over-ranges

Application Setting 0 - Disabled
17.20 Auto save menu 20 parameters on power down

Application Setting 1 – auto save
20.49 Application Software Version

Application Setting Software dependant
91.01 Fast Update Enable Key

Application Setting 3 – Enable Fast Speed Reference Update
7.1.2 Parameters set by software Permanently
1.10 Bipolar Reference Select

Application Setting 1 – Bipolar Enabled
1.14 Reference select

Application Setting 3 – Preset References
1.15 Preset Select

Application Setting 1 – Select 1.21 as reference

2.02 Enable Ramps
Application Setting 0 – Disable Ramps
2.04 Decel Ramp Mode

Application Setting 1 – Fast Ramps
5.18 Drive Switching Frequency

Application Setting 4.5 - 9Khz
6.01 Stopping Ramps

Application Setting 2 – stop without ramps
6.04 Sequencing Mode

Application Setting 4 – Wire-proof PLC Mode
6.15 Drive Enable

Application Setting Software Dependent
6.30 Sequencing Bit 0 (Run Forward)

Application Setting Software Dependant
91.05 Full Scale Speed

Application Setting Parameter 1.06
7.1.3 Drive Parameters set after a default (18.44 = 1)
8.10 T24 Digital I/O 1 Source / Destination

Application Setting 19.48 – Flying Shear Running
8.12 T24 Digital I/O 1 Output Select

Application Setting 1- Output

Application Setting 19.49 – Tool Enable Output

Application Setting 1 - Output

Application Setting 19.33 – Flying shear run input

Application Setting 0 - Input
8.19 T27 Digital I/P 4 Destination

Application Setting 18.32 – Home Switch Input

Application Setting 19.40 – Forward Hardware Limit

Application Setting 19.41 – Reverse Hardware Limit
8.25 Drive Relay Output Source

Application Setting 18.49 – Flying Shear Healthy
12.03 Threshold 1 Source

Application Setting 7.02 – Analog input 2
12.04 Threshold 1 Threshold

Application Setting 50 – 50%
12.05 Threshold 1 Hysteresis

Application Setting 1 – 1%
12.07 Threshold 1 Destination

Application Setting 19.38
If a Second Encoder (UD51) is fitted then:
16.10 Freeze Input Enable

Application Setting 1 – 1 Freeze Input Enabled

Application Parameters
7.1.4 Menu 18
18.01 Home State

Coding RO, Bi
Range: -3 to 5
Units: List
This indicates the condition of the Home Sequence
0 = STOP state
1 = Initialise
2 = Search for Home state
3 = Home detection state
4 = Position Offset state
5 = Preset final Home position/Completion state
ERROR States less than 0
-1 = Home disabled during home sequence
-2 = Home time exceeded timeout
-3 = Drive not Enabled
18.02 Home Complete

Coding RO, Bit
If set this parameter indicates that the home sequence has been completed.
18.03 Scan Time

Coding RO, Uni
Range: 1 to 500
Units: ms
Indicates the scan time of the Background task in ms.
18.04 Batch Counter (Count UP)

Coding RO, Uni
Range: 0 – 18.17
Units: Qty
Batch Counter, indicates the number of cut cycles completed.
18.05 Batch Counter (Count DOWN)

Coding RO, Uni
Range: 18.17 - 0
Units: Qty
Indicates the quantity remaining in the batch.

18.06 Batch Done
Coding RO, Bit
Indicates that the current batch is completed.
18.07 Minimum Registration Distance

Coding RO, Units
Indicates the minimum distance the shear can be away from the tool / material edge.
Add 10% to this distance to make sure the profile can be met.
18.08 Length of Last Cut 1

Coding RO, Uni
Range: 0 - 32000
Units: Units
Indicates the length of the last cut.
18.09 Length of Cut before Last Cut

Coding RO, Uni
Range: 0 - 32000
Units: Units
Indicates the length of the cut before the last cut 18.08.
18.10 Line Speed Indication

Coding RO, Uni
Range: ±32000
Units: Units/(min*18.18)
This parameter indicates the line speed in selected units per min. The units can be
scaled with the line speed scalar parameter 18.18.
18.10 = Selected Units (18.11/18.12) / 18.18
Example:
a. To display metres/min when the selected units are in millimetre set parameter
18.18 = 1000.
b. To display feet/min when the selected units are in 0.1inches set parameter
18.18 = 120.
NOTE This parameter is filtered to produce a steady indication of speed.

18.11 Units
Coding RW, Uni
Range: 0 to 9
Default settings: 0
Units: List
The CTIU uses this parameter to store the units that are selected by the CTIU
configuration. This parameter does not make any difference to the operation of the flying
shear, and is simply used as a non-volatile memory for the display.
0 = Undefined User units
1 = mm x 100
2 = mm x 10
3 = mm
4 = mm / 10
5 = mm / 100
6 = inches x 10
7 = inches
8 = inches / 10
9 = inches / 100
18.12 Master Scaling Denominator

Coding RW, Uni
Range: 1 to 32000
Default settings: 1
Units: Counts
Master encoder feedback scaling denominator.
NOTE This parameter is only read on power up and when update scaling (parameter 18.37) is
set to 1.
18.13 Master Scaling Numerator

Coding RW, Uni
Range: 1 to 32000
Default settings: 16384
Units: Counts
Master encoder feedback scaling numerator.
set to 1.

18.14 Slave Scaling Denominator
Coding RW, Uni
Range: 1 to 32000
Default settings: 1
Units: Counts
Slave encoder feedback scaling denominator.
set to 1.
18.15 Slave Scaling Numerator

Coding RW, Uni
Range: 1 to 32000
Units: Counts
Slave encoder feedback scaling numerator.
set to 1.
18.16 Enable Batch Control

Coding RW, Bit
Default settings: 0
Set to enable batch control to be used.
18.17 Batch Quantity

Coding RW, Uni
Range: 0 – 32000
Units: Qty
Quantity in a batch.
18.18 Line Speed Scalar

Coding RW, Uni
Range: 1 – 32000
Units: Scale
Refer to parameter 18.10.

18.19 Home Speed
Coding RW, Uni
Range: 0 – * see parameter description below
Default settings: 5
Units: Units / s
This parameter sets the speed that the home sequence will search for the home switch.
* This parameter is limited by the max. speed of the drive which is converted to
Units/sec, and it is derived as follows:
Max Speed Limit (Units/s) = (01.06 * 03.21 * 4 * 18.14 * 0.99) / (60 * 18.15).
The Max speed limit is 99% of the drive max speed, to allow some small margin for
positional correction, if required.
18.20 Home Mode

Coding RW, bit
Default settings: 0
This parameter determines the homing mode as follows:
0 – Home to the leading edge of home/limit switch
1 – Search for the leading edge of home/limit switch and home on next encoder
marker pulse.
NOTE Mode 1 is not possible with SinCos or Resolver feedbacks.
18.21 Home Back-off Speed

Coding RW, U
Range: 0 – * see description in parameter 18.19
Default settings: 1
Units: Percentage of 18.19
This parameter set the speed that the axis will back-off the Home / Datum switch.
18.22 Home Search Direction

Coding RW, Bit
Default settings: 0
This set the initial direction for searching for the home.
1 = Forwards
0 = Reverse

18.23 Home Acceleration / Deceleration
Coding RW, U
Range: 0 – 32000
Units: Units / s2
This parameter defines the acceleration and deceleration ramps for the homing
sequence.
18.24 Home Time

Coding RW, Uni
Range: 0 – 32000
Units: 0.01 Seconds
This parameter defines the time allowed for the homing sequence to complete.
18.25 Zero Position Preset

Coding RW, Uni
Range: 0 – 32000
Default settings: 0
Units: Units
This parameter sets the zero position for this axis. This distance is added in a negative
direction to the Home / Datum position.
18.26 Watchdog Trip Delay

Coding RW, Uni
Range: 0 – 32000
Units: ms
18.27 Watchdog Out Time Period
Coding RW, Uni
Range: 0 – 32000
Units: ms
The Watchdog is used for monitoring the health of a communications link.
The drive generates a clock signal with an on / off time set by parameter 18.27. The
clock signal is read by the remote device, which then sends the clock signal back to the
drive. If the received clock from the remote device does not change state within the
time set by parameter 18.26 then a fault condition occurs. This checks the
communication link is able to read and write to/from the drive.

18.28 Jog Speed
Coding RW, Uni
Range: 0 – * see description in parameter 18.19
Default settings: 5
Units: Units / s
Set the jog speeds for both forward and reverse.
18.29 Jog Acceleration Rate

Coding RW, Uni
Range: 0 - 32000
Units: Units / s2
Sets the acceleration rate for the flying shear axis jog.
18.30 Jog Deceleration Rate

Coding RW, Uni
Range: 0 – 32000
Units: Units / s2
Sets the deceleration rate for the flying shear axis jog.
18.31 Home Switch Polarity

Coding RW, Bit
Default settings: 1
Sets the polarity of the home switch input.
1 = Normally Closed
0 = Normally Open
For safety reasons a fail-safe normally closed switch is recommended.
18.32 Home Switch Input

Coding RW, Bit
Default settings: 0
This parameter is used as the home switch input, if a digital input is used, then it should
be written to this parameter. This parameter is controlled by Digital Input F6 from
default.

18.33 Tool Sync Enable
Coding RW, Bit
Default settings: 0
This parameter sets the failure mode of the flying shear when the tool-raised signal is
not received at the end of the normal synchronised period. There are two options:
Decelerate the flying shear, or we can stay synchronised to the master and stop the line,
the choice will depend upon the risk of damage to the tool, and the ability to stop the
production line within the available travel of the flying shear.
0 = Decelerate as normal (at the Jog Accel/Decel rate)
1 = Synchronise to the line
NOTE In angled shear mode (20.41 = 1) option 1 is not available, and has no effect.
18.34 Flying Shear Ready

Coding RO, Bit
Default settings: 0
If this parameter is set to one then the flying shear will attempt to start when parameter
19.33 is set to one.
18.35 Enable Feed Forward Term Filter

Coding RW, Bit
Default settings: 0
When enabled, a 40ms filter is introduced in to the speed feed forward term, which is
derived from the Master encoder speed feedback. This will help to reduce motor noise
in the slave when a low resolution master encoder has been fitted, or where there is a
low number counts per base unit for the master compared with the slave.
NOTE Enabling 18.35 will cause a small positional following error, when the master accelerates
or decelerates.
18.37 Update Scaling

Coding RW, Bit
Default settings: 0
This parameter is set to one to update the forward direction of the axis, the feedback
source and the scaling of the axis, it will return to zero automatically when completed.
This can only be performed when the shear is stopped. If 18.37 is set to 1 whilst the
shear is running, the update will only be actioned when the shear is next stopped.

18.38 Batch Count Reset
Coding RW, Bit
Default settings: 0
Resets the batch counters.
18.41 Last Cut

Coding RO, Bit
Indicates that the last cut in the batch is in progress, this can be used to slow the master
down, to reduce the waste product produced.
18.42 Tool Output Enable

Coding RO, Bit
This control bit is used with the UTIM interface. It ensures the tool is not activated on
power up, as the application module TTL output, on/off states are the inverse to what is
required.
18.43 Tool Cut Command

Coding RO, Bit
Default settings: 0
Can be used as a source for a digital output to trigger the tool to cut the product.
18.44 Default Parameters

Coding RW, Bit
Default settings: 0
Set to 1 to set the parameters to default.
18.45 Watchdog enable

Coding RW, Bit
Default settings: 0
A Communications watchdog can be used to monitor the health of a communications
link, the watchdog simply sends a clocked (0,1,0,1) signal to the remote device, and
expects to get a similar signal returned. This parameter enables the watchdog
monitoring.
18.46 Watchdog In
Coding RO, Bit
This parameter should be written to with a toggling bit from the remote communication
device, the remote device may simply send back the clock pulse that it receives from
parameter 18.48.

18.47 Watchdog Out
Coding RO, Bit
This parameter should be sent to the remote device, the parameter will toggle at a time
base set by parameter 18.27
18.48 Fast Ramp Enable

Coding RW, Bit
Default settings: 0
This parameter determines what happens when a software or hardware limit is hit or
reached.
0 = Shear pin stop, this will stop the shear instantaneously (no ramp) when a limit is
hit.
1 = Fast stop, this will ramp the shear to a stop when a limit is hit. The fast
deceleration rate is determined by parameter 20.34
18.49 System Healthy

Coding RO, Bit
Default settings: 0
This Parameter should be used as an interlock to stop the master, if this parameter = 0
then the flying shear is in a fault condition and the line / master should stop as quickly as
possible.
18.50 Real Time Cut Enable

Coding RW, Bit
Default settings: 0
When this parameter is set at 1, the tool cut time, 20.30, is set in real time, in
milliseconds and is not influenced by the line speed. The tool is fired at the beginning of
profile point 3 (see shear profile diagram, section 6.5).
When this is set at 0, 20.30 is only applicable at maximum speed. This time will increase
inversely proportional with line speed e.g. If 20.28 = 100 Units / s and 20.30 = 100ms, at
maximum line speed the cut time is 100ms, and at half maximum line speed the cut time
is 200ms.
7.1.5 Menu 19
19.01 Position Reference

Coding RO, Bi
Range: ± 32000
Units: Units
This parameter indicates the demand position of the flying shear axis.

19.02 Actual Position
Coding RO, Bi
Range: ±32000
Units: Units
This parameter returns the actual position of the flying shear axis.
19.03 FE Active
Coding RO, Bit
If Set to 1, this parameter indicates that the following error is outside the following error
limit, set by parameter 19.11
19.05 Following Error (0.001 Units)

Coding RO, Bi
Range: ±32000
Units: Units * 1000
This parameter returns the following error of the flying shear axis.
19.06 Following Error (Encoder Counts)

Coding RO, Uni
Range: ±32000
Units: Encoder Counts
This parameter returns the following error, based on the number of encoder counts error
for maximum resolution.
19.07 Flying Shear Status Word

Coding RO, Uni
This Parameter returns the current activity of the flying shear; it is coded in a bit-wise
form.
Bit Description
0 Jogging
1 Travelling To Start Position
2 At Start Position
3 Homing Sequence In Progress
4 System Homed
5 Flying Shear Cycle Running
6 Cyclic Mode Selected
7 0 = Local 1 = Remote
8 Registration Mode Selected
9 New Cam Is Being Calculated
10 Cam Is Ready

11 On Last Cut In batch
12 Batch Done
13 Shear Is Ready To Run
14 Alarm Active
NOTE When this parameter is viewed from the drive’s display, the decimal equivalent will be
shown e.g. bit 4 will be shown as 16 (24).

19.08 Max Cut FE Detected
Coding RO, Uni
Range: 0 to 32767
Units: 0.01 Units
This parameter shows the maximum peak cut following error detected in the previous
cut cycle. The maximum value is displayed at the end of profile segment 3 (see section
6.5), and reset during segment 1 & 2. This parameter should be used to set up
parameter 20.23; an upper value should be determined from several samples in 19.08,
then a reasonable margin added to give headroom before entering a value in 20.23.
19.10 Master Position

Coding RO, Bi
Range: ±32000
Units: Units
This parameter returns the position of the master axis.
19.11 FE Limit 0.001 Units

Coding RW, Uni
Range: 1 - 32000
Units: 0.001 Units
This parameter sets the allowable flowing error, before a fault condition is reported.
19.12 Velocity Feed Forward Gain

Coding RW, Uni
Range: 0 - 32000
Units: 0.001Kd/sec
Assuming the feedback for the flying shear is generated from the feedback device
mounted on the back of the motor, this parameter should always be set to 1000; any
other value will produce a steady state following error.
19.13 Proportional Gain

Coding RW, Uni
Range: 0 – 32000
Units: 0.01Kp
This parameter is the proportional gain for the position loop.

19.14 Forward Software Limit Position
Coding RW, Uni
Range: 0 - 32000
Default settings: 0
Units: Units
Forward Software limit for the flying shear.
19.15 Reverse Software Limit Position

Coding RW, Uni
Range: 0 - 32000
Default settings: 0
Units: Units
Reverse Software limit for the flying shear axis
19.16 Proportional Gain Output Limit

Coding RW, Uni
Range: 0 – 100
Units: % of max speed (01.06)
In the position loop the feed-forward gain will give the drive approximately the correct
speed reference, the proportional gain is then added to the feed-forward as a small trim
to keep the axis at the correct position, The proportional gain should not need to
generate any more that a fraction of the full speed of the axis, a typical value for this
parameter should by between 15 – 25% of motor maximum speed set in parameter
01.06.
19.17 At Position Tolerance

Coding RW, Uni
Range: 0 – 32000
Units: Units / 1000
This defines the allowable error when the axis is in a set position.

19.18 Alarm Word
Coding RO, Uni
19.19 Alarm / Trip Selection Mask Word
Coding RW, Uni
Range: 0 – 16383
19.20 Trip Conditional Select Mask Word
Coding RW, Uni
Range: 0 – 16383
19.21 Alarm / Trip Enable Mask
Coding RW, Uni
Range: 0 – 16383
19.22 Raw Alarm / Trip Data
Coding RO, Uni
The parameters 19.18 – 19.21 are arranged with the following bit functions.
0 Tool did not rise at the end of the cycle – alarm only
1 *Following Error Outside Limit
2 **Other tool error
3 Start-up cut not done as master not stationary
4 Cam calculation parameter fault
5 Master Speed too fast
6 Sequence abort parameter fault
7 Homing Fault
8 Fwd H/W Limit
9 Rev H/W Limit
10 Fwd S/W Limit
11 Rev S/W Limit
12 Remote Fieldbus Trip
13 Watchdog fault error
*This can be: FE Limit (19.11) or Cut FE Limit (20.33)

**This can be: tool did not fire, tool is still in the product when shear is moved, or FE Cut
Limit is exceeded
Parameter 19.18 is the alarm word, and gives the status of all the current alarms
immediately that the alarms occur.
Parameter 19.19 selects whether the alarm should also trip the drive, set to 1 to trip the
drive and alarm, set to zero for alarm only.

Parameter 19.20 allows you to select when you want the trip to occur. If set to 1 then the
trip will occur at the same time as the alarm, if set to 0 then the trip will occur at the end
of the current flying shear cycle.
Parameter 19.21 allows you to enable / disable alarms and trips, set to 1 to enable
alarm and/or trip.
NOTE The alarms for the hardware and software limits cannot be disabled.
Parameter 19.22 contains the raw fault data that is used to generate the above
parameters.
When these parameters are viewed from the drives display, the decimal equivalent will
be shown e.g. bit 4 will be shown as 16 (24).
19.23 Gap Length

Range: 0 – 32000
Coding RW, Uni
Default settings: 0
Units: Units
If Gap mode is enabled then this parameter is used to set the length of the gap. A Gap
is produced between cuts, by adding a trapezoidal profile on to the cam. Length,
acceleration rate and speed are required to determine the required profile.
19.24 Gap Accel

Coding RW, Uni
Range: 0 – 32000
Default settings: 0
Units: Units/s2
This parameter is used to set the acceleration and deceleration rate for the gap
producing profile.
19.25 Gap Relative Speed

Coding RW, Uni
Range: 0 – 32000
Default settings: 0
Units: Units/s
This parameter is used to set the relative speed for the gap producing profile. This
speed + the profile speed, must not exceed the drive maximum linear speed, see
section 6.7.

19.26 Cut Mode
Coding RW, Uni
Range: 0–3
Default settings: 0
The cut mode determines how the up and down inputs are used:
0 = Does not use tool up/down inputs for feedback
1 = Use cutter up input only to check that the tool is clear prior to decelerating
2 = Use cutter down input only to give the shear the signal when to remove the
tool cut signal. If the tool down signal is not present at the end of the cut
period then the tool will rise and a fault condition will be set.
3 = Use both up and down.
See also section 6.8
NOTE In Angled Shear only modes 0 and 1 are available. If a tool up error is detected, at the
end of a cut, the shear will stop before the return part of the cycle (Cam point 6) can
happen. For this reason it is important to leave extra cut length to make sure the tool is
clear of the material when a fault is detected, otherwise the tool may be damaged.
19.27 Cut on start of Shear Cycle

Coding RW, Bit
Range: 0–1
Default settings: 0
If this input is set to one then the shear will always perform an initial cut prior to going
into run mode, this is so that the first cut can be of the correct length. This function is not
available in Angled Shear mode (20.41 = 1).
19.30 First Cut Mode

Coding RW, Uni
Range: 0–3
Default settings: 0
This parameter is used to define how the first cut is performed when the flying shear is
operating in cyclic mode. This may be used to ensure that the first cut is of the correct
length, and therefore eliminate any waste caused by the first cut.
0 = Cut Immediately (don’t worry about waste).
1 = Use registration once only to detect product edge, and cut one length later.
2 = Cut after a dwell of one cut length, this is used when the product starts off
aligned to the cutting tool.

19.31 Manual Tool Cut Command
Coding RW, Bit
Default settings: 0
Perform a manual cut when the master axis is stationary, or perform a scrap cut when
the shear is running.
A scrap cut can only be done when the shear is set to cyclic mode and the fast
optimisation mode is set (20.40).
Ensure that interlocks are present to prevent injury to persons.
19.32 Drive / Fault Reset

Coding RO, Bit
Default settings: 0
This parameter is the global reset, and will perform the same function as the drive reset
button, and it resets flying shear software alarms and trips.
19.33 Shear Run Command

Coding RW, Bit
Default settings: 0
If this parameter is set to one, on the rising edge, provided all of the interlocks are made
the flying shear will start to run, and will continue to run unless a fault condition develops
or the run command is removed.
Interlocks:
Hardware / software limits
Axis has been homed
Motion Abort 19.39 = 0
Axis is ready
When the axis starts it will:
• Go to the start position, defined by parameter 20.39.
• If Cut on start (parameter 19.27) is set then it will perform an initial cut cycle.
• Parameter 19.48 will be set to 1, this may be used as an interlock for the master to
start. The flying shear is then ready to run.
19.34 Go to Start Position

Coding RW, Bit
Default settings: 0
This parameter is used to send the flying shear axis to the start position that is defined
by parameter 20.39. This parameter requires a rising edge to initiate the move. The
Shear will move at the Jog speed and acceleration rate.

19.35 Local / Remote Control Select
Coding RW, Bit
Default settings: 0
This parameter defines where the command signals are generated, they may be
generated from a control word from a fieldbus using parameter _Sxx%, _Rxx%
NOTE The watchdog must be enabled to allow the Local / Remote mode to be set to remote,
this is done to prevent the flying shear from running / jogging or homing unexpectedly.
19.36 Jog Forward Command

Coding RW, Bit
Default settings: 0
Set to 1 to jog the flying shear axis forward. Requires a rising edge to initiate the motion,
and will continue while the signal is present
19.37 Jog Reverse Command

Coding RW, Bit
Default settings: 0
Set to 1 to jog the flying shear axis Reverse. Requires a rising edge to initiate the
motion, and will continue while the signal is present
19.38 Home / Datum Command

Coding RW, Bit
Set to 1 to home the flying shear axis. Requires a rising edge, the signal does not need
to be maintained. This is controlled from default by Analogue input 2 via Drive Menu 12.
19.39 Abort Motion Command

Coding RW, Bit
Set to 1 to stop all motion and trip the drive.
19.40 Fwd Hardware Limit Input

Coding RW, Bit
This parameter is used as the source for the forward hardware limit. The digital input
used for this limit switch input should be set with the destination set to this parameter.
This parameter is controlled by Digital Input F5 from default.

19.41 Rev Hardware Limit Input
Coding RW, Bit
This parameter is used as the source for the Reverse hardware limit. The digital input
used for this limit switch input should be set with the destination set to this parameter.
This parameter is controlled by Digital Input F6 from default.
19.42 Hardware Limit Polarity

Coding RW, Bit
Sets the polarity of the Limit switch inputs.
1 = Normally Closed
0 = Normally Open
For safety reasons a fail-safe normally closed switch is recommended.
19.43 Disable Limit Switches during homing

Coding RW, Bit
Default settings: 0
This parameter allows the user to disable the limit switches while the axis is homing, this
may be needed because the same switch is used for the limit switch and the home
switch, or because the limit switch is located inside the home switch. Care must be
taken if this feature is used to ensure that it cannot cause injury to persons or damage to
the machine if the home or datum switch fails to operate.
19.44 Change forward direction of slave

Coding RW, Bit
Default settings: 0
This parameter may be used to change the forward direction of the axis, however the
speed will indicate a negative speed when travelling forward. This is only read on
power-up or when the scaling is up-dated.
19.46 Tool Raised Input

Coding RW, Bit
This Parameter should be used to indicate that the tool is raised, and therefore that the
flying shear is decelerated. It is ORed with the UD70 TTL.0 input, so that either may be
used. If you are using the TTL inputs don’t use this parameter, set 19.46 to 0.
19.47 Tool Down Input

Coding RW, Bit
This Parameter should be used to indicate that the tool is fully down and is ready to rise.
It is ORed with the UD70 TTL.1 input, so that either may be used. If you are using the
TTL inputs don’t use this parameter, set 19.47 to 0.

19.48 Flying shear running
Coding RO, Bit
Default settings: 0
This parameter indicates that the Flying shear is running and the cam is enabled, this
parameter should be used as a ready interlock, or a start signal to the master / line.
19.49 Tool Enable

Coding RW, Bit
Default settings: 0
This parameter is used to enable the tool output to operate, however, it should not be
used as a safety feature, and an external fail-safe device that is able to inhibit the tool
from operating should be used to protect persons from injury or damage to the machine.
If this parameter is not set to 1, the batch control will not function.
19.50 Gap Enable

Coding RW, Bit
Default settings: 0
This parameter is used to enable a trapezoidal profile to be added to the cam profile to
produce a gap between flying shear cycles, it can only be used in the parallel shear
mode.
NOTE Using this mode takes additional processor resources and in some cases especially
where fieldbus options are used may cause intermittent nuisance trips.
NOTE This feature is not available in Angled Shear mode (20.41 = 1).
7.1.6 Menu 20
Parameters 20.01 to 20.19 are reserved for Fieldbus set up parameters. Please refer to
the following list of manuals for the parameter allocations and set-up.
Manual Description CT Part Number
Profibus-DP 0460-0075
Interbus 0460-0076
Modbus-Plus 0400-0035
CTNet 0460-0025-03
Devicenet 0460-0077
CAN 0460-0063
CANOpen 0460-0061
UD70 RS485 Port 0460-0098
(CTANSI, Modbus RTU, custom)

20.20 Tool Width Compensation
Coding RO, Uni
Range: 0 – 32.000
Default: 0
Units: Units / 1000
This parameter allows for the tool width to be added to the required cut length. This
compensation is useful where a saw is used as a cutting tool.
20.21 Minimum Cut Length

Coding RO, Uni
Range: 0 – 32000
Units: Units
This parameter reports the minimum cut length that can be achieved with the current
parameters.
20.22 Cam Status Word

Coding RO, Uni
Range: 0-5
This parameter returns the status of the flying shear profile calculation.
0 = Cam Calculated OK
Faults
Bit 0 = Insufficient travel available for the flying shear to perform flying shear profile
Bit 1 = Cut length is not achievable with flying shear profile parameter.
Bit 2 = Master is too fast, slave is unable to synchronise
20.23 Flying Shear Profile Control Mode

Coding RW, Bit
Range: 0–1
Default: 0
This parameter is used to specify the operation of the flying shear.
0 = Cyclic cut without registration
1 = Cut on registration mark
20.24 Cut Length

Coding RW, Uni
Range: 0 - 32000
Default 500
Units: Units

This parameter has different functions depending upon parameter 20.23.
If parameter 20.23 is set for cyclic cut, this parameter is used to set the cut length.
If parameter 20.23 is set for Registration, then this parameter is used to set the
windowing distance.
20.25 Shear Length / Shear Angle

Coding RW, Uni
Range: 1 – 32000
Default: 1000
Units: Units / 0.01degrees
This parameter depending upon the application / the operating Mode changes
definition:
Parallel Shear
The shear length is used to ensure that the flying shear profile does not attempt to
exceed the available travel. This parameter should be entered as the amount of
travel available from the start position of the flying shear to just before the forward
software limit.
Angled Shear
This parameter defines the angle between the flow of the product and the shear
carriage in units of 0.01 degrees
20.26 Fly Acceleration / Deceleration Rate / Start Distance

Coding RW, Uni
Range: 0 – 32000
Default: 50
Units: Units / s2 / Units
This parameter defines the acceleration and deceleration rate for the fly part of the
profile in Parallel Shear mode.
In Angled Shear mode, this parameter sets the Start Distance. The start distance is
equal to 20.29 + an offset to make sure the tool is up to speed before cutting the
material. This value can never be smaller than 20.29. See section 6.10.
20.27 Return Acceleration / Deceleration Rate

Coding RW, Uni
Range: 1 – 32000
Default: 50
Units: Units / s2
This parameter defines the maximum acceleration and deceleration rate when the axis
is returning to the start position, following the fly profile.

20.28 Maximum Master Velocity
Coding RW, Uni
Range: 1 – 32000
Default: 48
Units: Units / s
This parameter defines the maximum velocity that the master is expected to travel, it is
used for calculating the profile, the master must not exceed this speed.
20.29 Settling time / Accel Distance

Coding RW, Uni
Range: 0 to 32000
Default: 50
Units: ms / Units
The function of this parameter depends upon the operating Mode:
Parallel Shear
The synchronised part of the fly profile is broken down into three areas, settling
time, tool down time, and tool up time.
The settling time defines the number of ms that are required to recover following
error following the acceleration of the flying shear.
Angled Shear
This parameter defines the distance over which the shear can be accelerated to
sync speed.
20.30 Cut Time / Sync Distance

Coding RW, U
Range: 0 to 32000
Default: 50
Units: ms / units
definition:
Parallel Shear
The cutting time is used to specify the number of ms that the tool cut output needs
to be on to perform the cut. E.g. Tool down time.
Angled Shear
This parameter defines the distance (units) over which the shear must be
synchronised with the product. This must include enough distance to make sure the
tool has come out of the material after the cut. See section 6.10.

20.31 Tool Up time / Decel Distance
Coding RW, Uni
Range: 0 to 32000
Default: 50
Units: ms/units
definition:
Parallel Shear
The Tool up time is used to specify the number of ms required for the tool up input to
be received after the tool cut signal is removed.
At the end of this time the tool up input is interrogated and action is taken according
to the setting of parameter 18.33
Angled Shear
This parameter defines the distance over which the shear can be decelerated from
sync speed to a stop.
20.32 Cut Length Fine Adjustment

Coding RO, Uni
Range: 1 - 32000
Default: 0
Units: Units / 1000
This parameter is used to provide a fine adjustment to the required cut length.
20.33 FE Cut Limit

Coding RW, Uni
Range: 1 - 32000
Default: 0
Units: Encoder Counts
This parameter is used to specify the acceptable following error during the cut part of
the profile.
20.34 Fast Decel Rate

Coding RW, U
Range: 1 - 32000
Default: 0
Units: Units/s/s
This parameter is used to specify the rate at which the flying shear will decelerate if a
software or hardware limit is hit.

20.35 Ramp Mode
Coding RW, Bit
Range: 0-1
Default: 0
If this parameter is set to 1 then s-ramps will be used for the flying shear profile.
NOTE Using this mode takes additional processor resources and in some cases especially
where fieldbus options are used may cause intermittent nuisance trips.
20.36 Cam Pointer

Coding RO, Uni
Range: 0 – 10
This parameter returns the position of the cam pointer.
20.37 Enable Virtual Master

Coding RW, Bit
Default settings: 0
A virtual master may be used for commissioning the application, so that the profiles can
be seen without any risk of damage to the machine.
Set to 1 to enable the virtual master.
20.38 Virtual Master Speed

Coding RW, Uni
Range: 1 – [max line speed - 20.28]
Default: 50
Units: Units / s
Set the speed at which you want the virtual master to run.
NOTE The virtual master has no ramps.
20.39 Flying Shear Start Position

Coding RW, Bi
Range: ±32000
Default: 0
Units: Units
This sets Flying Shear start position from Zero position. (18.25).

20.40 Shear Optimisation Mode
Coding RW, Bit
Default: 1
This parameter is used to select the mode of optimisation for the return part of the shear
profile when in cyclic mode.
0 = Slow
1 = Fast
In slow mode the shear will return to the start position at the minimum speed, but with
enough pace to immediately start the next cut without the need to stop.
In fast mode the shear will return at the maximum accel, decel and speed, and will then
dwell at the start position before beginning the next cycle. Refer to parameter 19.31
manual cut for scrap cuts setup. If Registration is used, fast return is preferred.
20.41 Angled Shear Enable

Coding RW, Bit
Range: 0–1
The software is able to handle both parallel flying shears and Angled flying shears,
where the shear is positioned at an angle to the production flow.
20.42 Registration Fine Offset

Coding RW, Uni
Range: ±32000
Default: 0
Units: Units / 1000
The distance between a Registration sensor and the start position of the knife is set by
parameter 20.43, This parameter gives a fine offset to allow higher accuracy.
NOTE This should be set to a positive value, provided that registration sensor is before the knife
in the direction of the material flow.
20.43 Registration offset

Coding RW, Uni
Range: ±32000
Default: 0
Units: Units
Distance between the registration sensor and the flying shear start position.

20.44 Registration Window Enable
Coding RW, Bit
Default: 0
Set to 1 to enable registration windowing.
20.45 Registration Window Tolerance

Coding RW, Uni
Range: 0 – 32000
Units: Units
Default: 0
This parameter is used to set the open and close position for the window and any marks
detected outside the tolerance will be rejected.
Parameter 20.24 is used to set the distance for the centre position of the window.
20.46 Preset Master Position command

Coding RW, Bit
Default: 0
On the rising edge this parameter is used to preset the position of the master axis to the
value in parameter 20.47, so that the windowing function can be used.
20.47 Master Position Preset Value

Coding RW, Bi
Range: ±32000
Units: Units
Default: 0
This value is used to preset the master position on the rising edge of parameter 20.46
20.49 Application Software Version

Coding RO, U
7.1.7 PLC Registers

The following Application PLC registers are reserved for internal use and should not be
used or written to via serial communications:
71.51 to 71.71 and 71.96 to 71.99
The following Application PLC registers are used for serial communications control and
status word:
72.69 – Fault word
72.70 – Status Word 1
72.71 – Status word 2
73.70 – Control word
Refer to section Serial Communications / Fieldbus Control for more details.

8 Error Handling / Trouble Shooting
8.1 Application Error Handling
As the system is designed to be as flexible as possible, some trips may or not be
required depending upon the individual application, and so we have given the system
engineer the flexibility to do a risk analysis and decide how the errors are handled.
Options available:
• No alarm, no trip
• Alarm & no trip
• Alarm & trip Drive Immediately
• Alarm & trip drive if idle or otherwise after current flying shear cycle
These are set using three registers that contain an individual bit for each of the error
states:
Bit Description
0 Tool did not rise at the end of the cycle – Alarm only
1 Following Error Outside Limit
2 Other tool error
3 Start Cut Error, master not stationary
7 Homing Fault
8 Fwd H/W Lim
9 Rev H/W Lim
10 Fwd S/W Lim
11 Rev S/W Lim

Issue Number: 4
19.07 / 5
Raw Fault Data 19.22 / n Shear Running

19.18 / n
Enable Alarm / Trip 19.21 / n Trip x
Alarm
19.19 / n

19.20 / n
Enable Trip Trip immediatley / when
shear stopped
98
8.1.1 Trip Codes
Trips 40 to 60 - UD70 / Comms option module trips
(Refer to UD70 User Guide)
Trips 80 to 94 – Application specific trips
Trips 95 to 99 – Application standard trips
Trip Number Description

Tr80 Tool Did not rise at the end of the cycle
Tr81 FE Limit Error
Tr82 Other tool error
Tr83 Start Cut Error, master not stationary
Tr84 Profile Calculated Incorrectly
Tr85 Master Over speed Error
Tr86 Sequence Abort Parameter 19.39
Tr87 Homing Error, Refer to 18.01 for Details
Tr88 Forward Hardware Limit Error
Tr89 Reverse Hardware Limit Error
Tr90 Forward Software Limit Error
Tr91 Reverse Software Limit Error
Tr98 Remote Fieldbus Trip
Tr99 Communications Watchdog Error
Trip 80
This alarm / trip is set when the tool is not up at the end of the flying shear cycle, it is
only used only if Tool Sync parameter 18.33 is set to 1, the trip will only occur when the
axis is stationary, and so trip immediately is disabled.
Trip 81
This trip can be caused by either a general following error trip, which is set when the
following error exceeds the value set by parameter 19.11 or when the following error is
exceeds parameter 20.33 during a cut cycle, in the later case the following error is only
checked before the tool is fired.
Trip 82
This trip can occur for a number of reasons, refer to parameter 19.26 for modes:
Tool not up at the start of the cut cycle
Tool not up at the end of the sync period
The tool down signal is not set at the end of the cut period
The following error is exceeded, and cut is aborted

Trip 83
This trip will occur only if cut on start parameter 19.27 is set, and occurs when the
master axis is not stationary to allow the cut to take place.
Trip 84
The flying shear profile cannot be achieved. This should not cause a dangerous
condition, as the old profile will continue to be used until a suitable cam is calculated.
The cause for the calculation error is given by parameter 20.23.
Trip 85
Master speed exceeds the value set by parameter 20.28 by more than 10%.
Trip 86
Sequence abort parameter 19.39 is set to 1.
Trip 87
A homing fault has occurred, such as the home sequence has taken to long and has
timed out. Refer to parameter 18.01 for more detail.
Trip 88 – 91
Hardware and Software Limits
Trip 98
Set by the remote control word, parameter _S70% bit 7.
Trip 99
This trip occurs if the watchdog is enabled (parameter 18.45 is set), and is caused by a
communication loss between a remote device and the UD70.
8.1.2 Drive Trip Recovery

When the drive trips the application programme will be reset when the drive is reset.
However, the cause of the trip may still be present, such as a hardware limit may be
active, the application software will prevent the drive from tripping again so that the
cause of the problem can be fixed, but will prevent the system from restarting until the
trip condition is reset. If for example the forward hardware limit is hit and this trips the
drive, after a reset, the only operation that the drive will be able to perform will be jog
reverse, to move the axis off the limit switch. Following a drive trip 19.32 must be
toggled to reset the system,and a homing sequence must be performed.
9 Advanced Features
9.1 Serial Communications / Fieldbus Control
9.1.1 Control Word _S70% (Parameter 73.70)
Introduction
The fieldbus control word is an efficient way of remotely controlling the motion of a
Drive. Due to the restriction of most fieldbus word length the control word length will be
no more than 16bits, UD70/MD29 PLC register _S70% will be used to ensure full
resolution is maintained (e.g. drive parameter limited to 32000 or 1000).
Each bit in the fieldbus control word has a particular function, and provides a method of
controlling the output functions of the Drive (RUN, JOG, TRIP, etc.) with a single data
word, (16Bits).
To use the fieldbus control word, the ENABLE terminal on the drive must be closed, and
the MASK bit must be set to 1. The 0-1 transition of the MASK bit will cause the digital I/
O control to be switched from local terminal mode to fieldbus control.
When the MASK bit is reset to 0, the Digital I/O control is switched terminal control
mode.
A selector switch can also be used to select between local (terminal) and remote
(fieldbus) control of the Drive. If a digital input is configured to directly control mode
parameter assigned (MM.PP), the value written by the Main Title interface will be
immediately overwritten by the digital input.
NOTE If you use the SYPT watch window or similar monitoring tool for the purpose of
commissioning, you must have the Watchdog enabled (18.45 = 1), and the Watchdog
trip disabled (19.21 bit 13 = 1).
Bit Function Description
0 ENABLE Must be set to 1 to put the Unidrive in READY mode. Resetting to 0
will immediately disable the Drive, and the motor will coast to stop.
1 Run Set to 1 to run the flying shear cycle, when reset to zero the flying
shear will stop at the end of the current cycle.
2 Jog FWD Set to 1 to run the motor in the forward direction. When reset to 0,
the motor will stop
3 Jog REV Set to 1 to run the motor in the Reverse direction. When reset to 0,
the motor will stop
4 MASK A 0-1 transition of this bit will set MM.PP to 1 to enable fieldbus
control of the Drive. 19.35 can subsequently be over-written by a
digital input if a terminal or fieldbus control selector switch is required.
(A 1-0 transition will reset 19.35 to 0.)
5 Reserved
6 RESET A 0-1 transition will reset the drive from any trip condition. If the
cause of the trip has not been cleared, the Drive will not trip again
immediately.
7 TRIP A 0-1 transition will force a “tr98” trip on the Drive. If the RESET and
TRIP bits change from 0 to 1 on the same cycle, the TRIP bit will take
priority.
8 Home A 0-1 transition will initiate a homing sequence
9 Tool If set to 1 then the cutting tool is enabled
Enable
10 Start Pos A 0-1 transition will command the drive to travel to the start position.
11 Save Pars A 1-0 transition with perform a Save of parameters
14 WDin Watchdog In - Comms clock from remote device.
15 WDout Watchdog out - Comms clock to remote device.
The recommended control method for the PLC program is to reset the fieldbus control
word to a safe state, e.g. Drive disabled. When a fault is detected with either the
Application software or communication link, the Drive control word is reset to 0
automatically when the Drive trip is reset. When the Serial Communication link is
healthy again, the appropriate fieldbus control word can be set, the Drive control word
will in turn be updated and the Drive will restart. Some example fieldbus control word
values to control the Drive are given in the table below.
Wdin is the communication watchdog bit transmitted from remote intelligent device,
(PLC, keypad or CTIU, etc).
9.1.2 Fault Word _R69% (Parameter 72.69)
The Fault word returns the current fault status of the drive.
Bit Description
0 Tool Raised Switch Error
1 Following Error Outside Limit
2 Tool did not rise at end of the cut sequence
7 Homing Fault
8 Fwd H/W Lim
9 Rev H/W Lim
10 Fwd S/W Lim
11 Rev S/W Lim
13 Watchdog Error
9.1.3 Status Words _R70%, _R71%

Status Word 1 _R70% (Parameter 72.70)
Bit Parameter Description

0 10.01 Drive healthy
1 10.02 Drive Output Stage Active
2 10.03 Zero speed
3 8.07 & 06.15 Drive Enabled (Ready)
4 01.11 Reference ON
5 - Master Speed Is At Zero
6
7
8
9
10
11
12
13
14
15
Status Word 2 _R71% (Parameter 72.71)
Bit Description
0 Jogging
1 Travelling To Start Position
2 At Start Position
3 Homing Sequence In Progress
4 Homing Completed
5 Flying Shear Cycle Running
6 Cyclic Mode Selected
7 0 = Local 1= Remote
8 Registration Mode Selected
9 New Cam is being Calculated
10 Cam is Ready
11 On Last Cut In Batch
12 Batch Done
13 Shear Is Ready To Run
14 Alarm Active
15 Watchdog Out
NOTE The watchdog must be enabled to allow the Local / Remote mode to be set to remote,
this is done to prevent the flying shear from running / Jogging and Homing unexpectedly.
Parameter 19.07 contains the same information as _R71%.
CTIU – Operator Panel

The CTIU operator interface enables the user to monitor, set-up and control the flying
shear application remotely without the need to use the manual or Unidrive parameter
numbers. All parameters are displayed in text rather than using it’s Unidrive parameter
number. Textual descriptions are also given for trips/alarms, Boolean statuses/settings
and selection parameters. On line Help descriptions are available for further information
on the configuration parameters.
Front View of CTIU110
9.2 Software Version

CTIU Software Version – V01.00.00 or greater, this will be displayed on the CTIU
second splash screen or can be found under the ‘Drive Diagnostics’ menu
9.3 Mechanical Installation

Panel Cut-out Detail
5.95” [151mm]
+0.02 +0.5
3.27”-0.00 [83-0.0 mm]
UP TO 0.04”[1m m] CORNER
RADIUS IS ACCEPTABLE
CTIU11X CUTOUT DETAILS

TOLERANCES ARE + /- 0.01” [0.3mm] UNLESS STATED OTHERWISE
9.4 Electrical Installation
9.4.1 CTIU110 Rear View
24Vdc Power Supply Requirements (J1)

Peak Inrush – 240mA
Continuous – 100mA
9.4.2 Serial Communications Cable Connections
Unidrive Application Module
D-type male
7 3 6 2 1 Connector
Twisted 0.1MicroF
Pairs with Ceramic
overall
screen
2 3 4 5 6 7 8
Section of 13
RxD
TxD
Rx+
Tx+
Rx-
Tx-
0v
pin connector
RS422/485 RS232
CTIU
Recommended Cables
Belden No. 8105, 9807 or 9832 – General Purpose
Belden No. 8165 – Heavy Noise Environment
9.5 Unidrive set-up
The protocol used between the CTIU110 and the Unidrive applcation module is Modbus
RTU. To establish comunications the Unidrive Address, Baud rate and Protocol is
required to be set, the following table details the required parameters to be set:
Parameter Setting Description
17.05 11 Drive address

17.06 13 RS458 Modbus-RTU protocol mode
17.07 19200 Baud rate
NOTE Perform a Drive save to save these setting during power down.
e.g. XX.00 = 1000 followed by reset.
9.5.1 CTIU110 Configuration of the RS-485 Port
OFF
ON
SW1
Configuration Bank
The configuration bank sets the parameters of the RS-485 port as described in Table
4.1.
Configuration Bank Description

Switch 1 ON: Pull-up (must be used together with switch 3)
OFF: no Pull-up
Switch 2 ON: 120Ω termination
OFF: no termination
Switch 3 ON: Pull-down (must be used together with switch 1)
OFF: no Pull-down
Switch 4 Reserved for future use
NOTE
Switch 1 and 3 must be used together.

Either both pull-up and pull-down are used or neither is used.
Pull-up and Pull-down switches are used to increase the signal level on the RS-485
bus. This is useful if there is a long bus and a significant amount of attenuation is
anticipated.
Termination resistance of 120Ω must be placed across each end of the RS-485 bus.
With switch 2 ON, a 120Ω resistance is placed across the bus. This should only be used
if the CTIU050/100/110 is the last device at either end of the bus.
9.6 Operation Button Selection Actions

PAUSE key selects data for editing OR exits from data editing.
PAUSE & DOWN keys pressed together, enters sub menu pages.
PAUSE & UP keys pressed together, exits sub menus to the parent menu pages.
UP key selects the previous menu page, sub menu page, alarms, and increments data
DOWN key selects the next menu page, sub menu page, alarms and also decrements
data.
ENTER key sends data to the automation equipment, accepts alarms, and displays
accepted alarms.
ALPHANUMERIC KEYPAD and PROGRAMMABLE KEYS can be used to enter data
or can be used to preform some pre-programmed action.
Contrast Adjustment
On menu page 1 (after the start-up screen), hold the ENTER key and press the UP or
DOWN key to adjust the contrast. The contrast setting is stored and not lost after
removing power.
9.7 Navigation
The flying shear screens are split into 2 sections:
• Operator section
• Configuration section
The flying shear parameters are grouped into relevant application menus to aid with
efficient navigation to each parameter. Each menu has two parts,
A parent menu page, this is the menu header and displays the menu description.
Sub-menu page/s containing all the relevant parameters for the menu.
e.g. Parent Menu Page: I/O Diagnostics

Sub-menu Pages contain relevant parameter for the Parent Menu: -
All status of the Digital Inputs and Outputs Terminals: 1&2 and 24-30.
The current values on all Analogue input terminal: 05-08.
Using on-screen graphical icons the following sections describes how to navigate
between Parent and sub-menu screens.
9.7.1 Parent Menu Pages Navigation
Parent Menu Page Down

This signifies the parent menu
navigation direction. When this
symbol is shown, pressing the
'Down' key will display the next
parent menu page down from
the current.
Parent Menu Page UP

This signifies the parent menu
'Up' key will display the next
parent menu page up from the
current.
Sub-menu Access
This indicates the two keys that
need to be pressed to access
the Parent sub-menu.
e.g. to access the Process
Diagnostic sub-menu pages,
press the Pause and Down keys
together.
9.7.2 Sub Menu Pages Navigation
Help
Many of the configuration sub-
menu pages are provided with a
brief help description for each
parameter. Pressing the F10 key
will display the help information
for the parameters displayed on
the current sub-menu page .
Parent Menu Access

Press the Pause and the Up
keys together to go back to the
Parent menu page. This will be
indicated on the last page on
each sub-menu
Sub-menu Page Down

Sub-menu Page UP
This signifies the sub-menu
This signifies the sub-menu
'Down' key will display the next
'Up' key will display the next sub-
sub-menu page down from the
menu page up from the current.
current.
9.8 Operators Screens Description

The operator screens consist of:
• Top-level main page which provides an overview of all the important parameters of
the shear on one screen
• Diagnostic information for drive and the application
• Process set points.
These screens are detailed in the Operators navigation diagram shown below.
9.8.1 Top Level Screen and Functionality
System Start Key

(Selectable)
System Stop Key

(Selectable)
System Reset Key

(Selectable)
System Status
Idle
Jogging
Running
Positioning
Ready
Datum Status
System Datumed
System Not Datumed Datum
(Selectable)
Drive Health Monitoring
Drive Tripped / Alarm Jog Rev
Slave Pos / Cut Length (Selectable)
Position of the Slave and also
the desired cut length setpoint. Jog Fwd
(Selectable)
Help
Pause Button UP Button Down Button

Used with the up & For page navigation, For page navigation,
Retun Button
down keys to access Page UP, or for Page DOWN, or for
For accepting
sub-menus or to incrementing data decrementing data
required data entry
toggle between data entry values entry values
values
entry fields
The top-level screen indicates all the common variables for process/application, e.g. set
points, feedbacks, status etc. The Top-level screen is always the first menu Page to be
displayed. A Menu Timeout, safety feature is used to force the CTIU display focus back
to the first (main) menu page after a set time period. The Menu Timeout period is set to
300 seconds (5mins).
9.8.2 Diagnostic Screens

The following diagnostic screens are available:
Application Diagnostics
Displays parameters directly related to the process control, Feedback alarm thresholds;
Feedback; Current alarm status.
Drive Diagnostics
Displays parameters directly related to the Flying Shear drive, Frequency, Volts, Power,
Speed, DC Bus Volts, Current, Overload accumulator; Fault log; Software versions.
I/O Diagnostics
Displays parameters directly related to the Flying Shear drive inputs & outputs, Unidrive
standard and option digital status’s and analogue current values.
Operator Navigation
MAIN PAGE Sub-Menu Sub-Menu
Navigation Arrow Description

- Denotes navigation direction of the parent Menu pages.
This is achieved by using the up & down arrow keys on the CTIU.
- Denotes navigation direction between the parent menu page & sub-menu pages. (without password).
To access the sub-menu from the parent menu page press the pause and the down arrow keys together.
To go back to the parent menu page from the submenu press the pause and the up arrow keys together.
- Denotes navigation direction between the parent menu page & sub-menu pages. (with password).
This has the same functionality as the Blue arrow but a password is required before access to given to the
sub menu.
- Denotes navigation direction of the sub-menu pages.

This has the same functionality as the Black arrow.
Operator Navigation
Sub-Menu Sub-Menu Sub-Menu
Refer
to the Configuration
menu section

sub menu.

Configuration Navigation

sub menu.

1 2

sub menu.

Issue Number: 4
2
sub menu.
117
9.9 Access
To gain access to the Setpoints and Configuration menu’s a password must be entered.
To enter the password press the pause key, this will then highlight the password digits
(0000). After entering the password which is 9999, press the pause key a second time.
You will now be able to access the menu by pressing pause and down at the same time.
If it is desirable to give the shear operator Setpoint access only, the number 5555 should
be entered using the method above.
9.10 Splash Screens

There a two splash screens displayed in sequence during initial power up. These detail
the application and software version information.
9.10.1 Application Page (1st Page)
9.10.2 Software Version Page (2nd Page)
9.11 Parameter Save
When any of the editable data fields has been changed within the configuration menus
and the Top-level menu page (1) is display (due to timeout, or forced by the user), a
parameter save will be prompted to the operator.
9.11.1 Parameter Save Main Screen
This is the first screen to be displayed, where it indicates to the user to save parameters
by pressing Function key F8. To save the parameters the Unidrive must be in stopped
state, a flashing message will advise if a save can be performed.
e.g. Flashing Message
Drive Running – Stop Drive to Save
Drive Stopped – OK to Save
If a parameter save is not required the pause (||) key can be press to quit back to the
Top-level menu page (1).
9.11.2 Parameter Save Acknowledgement Screen
When function key F8 is press with the Drive stopped the above screen will appear
acknowledging a parameter save is being performed. After approximately 5 seconds the
top level menu page (1) will re-appear, confirming the save has completed.
9.12 Trip & Alarm indication
There are two types Alarm pages:
• Trip – Indication the system has tripped and needs a reset to resume operation.
(Unless the result of the trip has caused permanent damage)
• Alarm – Indication of alarms that will not stop the system but may restrict the
operation, or advise the process is close to or on process limits.
Starter alarms will lock out the corresponding starter and make it unavailable for
selection, these alarm require a reset to make the starter available again. Indication is
given where a reset is required with an alarm.
All pages have to be acknowledged by the pressing of the ‘Return’ key. This will remove
the Alarm page from the display only; this will not reset any trips or alarms on the drive.
A trip or alarm reset is a separate function and can be performed from the CTIU (F3 key
when feature is enabled), or from another source (Pushbutton, PLC, etc). When a trip or
an alarm is acknowledged but not reset, the Alarm page will be removed from the
display of the CTIU. To make the operator aware this is still a trip or an alarm still
present, the top level menu page (1), ‘Status’ data field will indicate that the system has
a ‘Fault’ or an ‘Alarm’ present. Pressing the ‘Return’ key while on the top-level menu
page (1) will toggle between the Alarm page and the top-level menu page. The alarms
and trips can also be review in the following ‘Diagnostic Menus’:
• Alarms – Process Diagnostics (page 1 of sub menu)
• Trips – Drive Diagnostics (Page 3 Last Fault logged)
9.12.1 TRIP Page (Alarm page 1)
Trip Description
Text table with reference to Unidrive parameter #10.20
Acknowledge
Press Return Key. This will not reset fault.
9.12.2 ALARM Page (Alarm page 2)
Alarm Description
Text table with reference to Internal variable %R0035
Acknowledge
Press Return Key. This will not reset alarms where required.
9.13 CTIU Function Keys Allocation
9.13.1 Global Control Function Keys
The following Function keys can be optionally configured from the Configuration
‘Optional Features’ menu. These function keys allow the flying shear application to be
fully controlled from the CTIU without the need for addition switchgear (switches,
pushbuttons etc). These function keys, when selected, are active on every display
focus, and will control the application provided the ‘Remote select ‘parameter is set
(19.35 =1):
F1 – Start, sets bit 1 of the control word when the function key is enabled and
pressed.
F2 – Stop, reset bits 1 of the control word when the function key is enabled and
pressed.
F3 – Reset, toggles bit 6 of the control word when function key is enabled and
pressed and resets to zero when released (pushbutton type).
F4 – Jog Forward, toggles bit 2 of the control word when the function key is
enabled and pressed. and resets to zero when released (pushbutton type).
F5 – Jog Reverse, toggles bit 3 of the control word when the function key is
enabled and pressed. and resets to zero when released (pushbutton type).
F6 – Datum, toggles bit 8 of the control word when the function key is enabled and
pressed. and resets to zero when released (pushbutton type).
N.B: When the keys are configured it is important to remember to press the Enter
key after changing a Function key setting, failure to do this will result in the key
reverting back to its previous setting.
NOTE When using the start/stop function keys to control the application it is advisable to enable
the communications watchdog, so the drive trips ‘TR99’, when the communication is lost.
9.13.2 Local Function Keys

The following are defined as local function keys as they are only apply to one or range
of pages.
• F10 – Call On-line help. This is only available in the configuration pages and
provides information for each parameter displayed on the current page.
• F8 – Parameter Save. This is only available when the parameter save status page
is displayed. When pressed will save the parameters within the drive and second
processor.
10 Quick Reference
10.1 Application Parameters - Menu 18, Menu 19 and Menu 20
10.1.1 Menu 18
No. Description Typ Units Range Default Setting
18.01 Home State RO List -3 – +5 -
18.02 Home Complete Flag RO Bit - -
18.03 Background Scan Time RO Ms 0 – 32000 -
18.04 Batch Counter (Count Up) RO Qty 0 – 32000 -
18.05 Batch Counter (Count Down) RO Qty 0 – 32000 -
18.06 Batch Done Flag RO Bit - -
18.07 Minimum Registration Distance RO Units 0 - 32000 -
18.08 Length of last cut RO Units 32000 -
18.09 Length of cut before last cut RO Units 32000 -
18.10 Line Speed Indication RO Units / min * 18.18 32000 -
18.11 Units RW List 0–9 0
18.12 Master Scaling (Denominator) RW Counts 1 – 32000 1
18.13 Master Scaling (Numerator) RW Counts 1 – 32000 16384
18.14 Slave Scaling (Denominator) RW Counts 1 – 32000 1
18.15 Slave Scaling (Numerator) RW Counts 1 – 32000 16384
18.16 Enable Batch Control RW Bit - 0
18.17 Batch Quantity RW Qty 0 – 32000 10
18.18 Line Speed Scalar RW - 1-32000 1000
18.19 Home Speed RW Units / s 0–* 5
18.20 Home Mode RW Bit 0–1 0
18.21 Home Back-off Speed RW Units / s 0–* 1
18.22 Home Search Direction RW Bit - 0
18.23 Home Accel / Decel RW 2 0 – 32000 50
Units / s
18.24 Home Time-out RW 0.01sec 0 – 32000 500
18.25 Zero Position Preset RW Units 0 – 32000 0
18.26 Watchdog Trip Delay RW ms 0 – 32000 2200
18.27 Watchdog Output Time Period RW ms 0 – 32000 700
18.28 Jog Speed RW Units / s 0–* 5
18.29 Jog Acceleration Rate RW Units / s2 0 – 32000 100
18.30 Jog Deceleration Rate RW Units / s2 0 – 32000 100
18.31 Home Switch Polarity RW Bit - 1
18.32 Home Switch Input RW Bit - -
18.33 Tool Sync Enable RW Bit - 0
18.34 Drive Ready RO Bit - -
18.35 Enable Feed Forward Term Filter RW Bit - -
18.37 Update Scaling RW Bit - 0
18.38 Batch Reset RW Bit - 0 -
18.41 Last Cut Flag RO Bit - - -
18.42 Tool Output Enable RO Bit - - -
18.43 Tool Cut Output RO Bit - -
18.44 Default Parameters RW Bit - 0
18.45 Watchdog Enable RW Bit - 0
18.46 Watchdog In RW Bit - 0
18.47 Watchdog Out RO Bit - -
18.49 System Healthy Output RO Bit - -
18.50 Real Time Cut Enable RW Bit - 0
10.1.2 Menu 19
19.01 Position Reference RO Units +/-32000 -
19.02 Actual Position RO Units +/-32000 -
19.03 FE Active RO Bit - -
19.05 Following Error (Units) RO 0.001 Units +/-32000 -
19.06 Following Error (Enc Counts) RO Counts +/-32000 -
19.07 Flying Shear Status Word RO - - -
19.10 Master Position RO Units +/-32000 -
19.11 FE Limit RW 0.001 Units 1 – 32000 100
19.12 Position Loop Velocity Feed Forward Gain RW 0.001Kd / s 0 – 32000 1000
19.13 Position Loop Proportional Gain RW 0.01Kp 0 – 32000 1600
19.14 Forward Software Limit RW Units 0 – 32000 0
19.15 Reverse Software Limit RW Units 0 – 32000 0
19.16 Proportional Gain Output Limit RW Percent of 01.06 0 – 100% 10
19.17 At Position Tolerance RW Units / 1000 0 – 32000 1000
19.18 CTIU Alarm Word RO - - -
19.19 Alarm / Trip Select Word RW - 0 – 16383 16383
19.20 Trip Conditional Select Word RW - 0 – 16383 8064
19.21 Alarm / Trip Enable Word RW - 0 – 16383 16383
19.22 Fault Input Word RO - - -
19.23 Gap Length RW Units 0 – 32000 0
19.24 Gap Accel / Decel Rate RW Units / s2 0 – 32000 0
19.25 Gap Relative Speed RW Units / s 0 – 32000 0
19.26 Cutter IO Mode RW Bit 0–3 0
19.27 Cut before start RW Bit - 0
19.30 First Cut Mode RW Bit 0–2 0
19.31 Manual Cut Command RW Bit - 0
19.32 Drive / Fault Reset RW Bit - 0
19.33 Shear Run Command RW Bit - 0
19.34 Go to Start Position RW Bit - 0
19.35 Local / Remote Select RW Bit - 0
19.36 Jog Forward RW Bit - 0
19.37 Jog Reverse RW Bit - 0
19.38 Home Command RW Bit - 0
19.39 Abort Motion Command RW Bit - 0
19.40 Forward Hardware Limit Input RW Bit - 0
19.41 Reverse Hardware Limit Input RW Bit - 0
19.42 Hardware Limit Input Polarity RW Bit - 0
19.43 Disable Limits During Homing RW Bit - 0
19.44 Change Forward Direction RW Bit - 0
19.46 Tool Up Input RW Bit - 0
19.47 Tool Down Input RO Bit - 0
19.48 Flying Shear Running RO Bit - 0
19.49 Tool Enable RO Bit - 0
19.50 Gap Enable RW Bit - 0
10.1.3 Menu 20
20.20 Tool Width Compensation RW Units 0 – 32.000 0
20.21 Minimum Cut Length RO Units - -
20.22 Cam Status Word RO - - -
20.23 Flying Shear Profile Mode RW Bit - -
20.24 Cut Length RW Units 1 – 32000 500
20.25 Shear Length RW Units 1 – 32000 1000
20.26 Fly Accel / Decel Rate RW Units / s2 1 – 32000 50
20.27 Return Accel / Decel Rate RW Units / s2 1 – 32000 50
20.28 Maximum Master Velocity RW Units / s 1 – 32000 48
20.29 Settling Time / Accel. Distance RW ms / units 0 – 32000 50
20.30 Cut Time / Sync Distance RW ms / units 0 – 32000 50
20.31 Tool Up Time / Decel. Distance RW ms / units 0 – 32000 50
20.32 Cut Length Fine Adjustment RW 0.001 Units 0 – 32000 0
20.33 FE Cut Limit RW Counts 1 – 32000 500
20.34 Fast Deceleration Rate RW Units / s2 1 – 32000 0
20.35 Ramp Mode RW Bit - 0
20.36 Cam Pointer Position RO - 0 – 10 -
20.37 Enable Virtual Master RW Bit - 0
20.38 Virtual Master Speed RW Units / s 0 – [20.28] 10
20.39 Flying Shear Start Position RW Units +/- 32000 0
20.40 Shear Optimisation Mode RW Bit - 0
20.41 Flying Shear Type Parallel / Angled RW Bit - 0
20.42 Registration Fine Offset RW 0.001 Units 0 – 32000 0
20.43 Registration Sensor Position RW Units 0 – 32000 0
20.44 Registration Window Enable RW Bit 0 – 32000 0
20.45 Registration Window Tolerance RW Units 0 – 32000 20
20.46 Preset Master Position Command RW Bit - 0
20.47 Master Preset Position Value RW Units +/- 32000 0
20.49 Application Software Version RW - 0 – 32000 -
11 Documentation Reference
Manual Description CT Part Number
Unidrive User Guide 0460 - 0083 - 08
2nd Encoder Interface User Guide 0460 - 0084
SinCos Interface User Guide 0460 - 0085

Resolver Interface User Guide 0460 - 0088
Unidrive Advanced User Guide 0447 - 1001
Profibus-DP Interface 0460 - 0075
Interbus Interface 0460 - 0076
Modbus-Plus Interface 0400 - 0035
CTNet Interface 0460 - 0025 - 03
Devicenet Interface 0460 - 0077
CAN Interface 0460 - 0063
CANOpen Interface 0460 - 0061
UD70 RS485 Port 0460 - 0098
(CTANSI, Modbus_RTU, custom)
12 Signal Interface Unit
12.1 U.T.I.M.
The U.T.I.M. (Universal Type-Interface Module) is a DIN rail mountable unit.
It is designed to help the user by providing conversion between standard signal levels.
It has three channels of conversion - these are:
Channel Input Signal Type Output Signal Type
A +24V (+12 > +25V) RS-422 and TTL(inv)

B +24V (+12 > +25V) RS-422 and TTL(inv)
C ‘TTL’ TTL +24V (equal to supply
C ‘Enable’ +24V voltage)
Channels A and B are intended for interfacing a 24volt signal with RS485 / RS422 level
inputs or TTL inputs such as those on the UD70. Both inputs are OPTO-isolation from
the main circuit for isolation and noise rejection. Channel C is used for converting a TTL
level output to a useful 24volt signal that is typically capable of driving sufficient current
to operate a solenoid directly or a relay. It is an open-collector type of output and so a
load (shunt) resistor will be required if the output is driving a high impedance load.
Channel C ‘TTL’ and ‘Enable’ inputs do not have OPTO-isolation. The channel C output
is inverted with respect to it’s (TTL) input and is only enabled when a signal is applied to
the ‘Enable’ input. The ‘Enable’ input uses positive logic with respect to the channel C
output, therefore the ‘TTL’ input must be LOW and the ‘Enable’ input must be HIGH in
order to derive an output.
Issue Number: 4
Term 18/20
Identical for
Inversion /TTL
channels A and B Indication
Term 21-22/
Term 4/6 OPTO- 23-24
+24V isolation > TTL > 422 RS-422
TTL
Indication Indication
Term 2
+Vsupply Term 32
Term 8
TTL Inversion Channel C
Output
AND Output Driver Term 31
Indication
Term 10
+24V
0V Term 1
Enable
128
Connector 1
Terminal Usage Polarity Notes
1 Power in 0V common*
2 Power in +V common**
3 Input A 0V isolated
4 Input A +V isolated
5 Input B 0V isolated
6 Input B +V isolated
7 Input C TTL 0V common*
8 Input C TTL +V
9 Input C +24V 0V common*
10 Input C +24V +V
11 User Vs out 0V common*
12 User Vs out +V common**
Connector 2
Terminal Usage Polarity Notes
17 /TTL out A 0V common*
18 /TTL out A +V
19 /TTL out B 0V common*
20 /TTL out B +V
21 422 out A -V (inv)
22 422 out A +V
23 422 out B -V (inv)
24 422 out B +V
31 Ch. C out 0V
32 Ch. C out +V common**
* 0V common
** Vs common
12.2 U.T.I.M. 2
The U.T.I.M. 2 (Universal Type-Interface Module) is a DIN rail mountable unit.
It is designed to help the user by providing conversion between a range of standard
signal types, such as +24V, TTL and RS485.
All of the UTIM 2 inputs are optically isolated from the main circuit for electrical isolation
and improved noise rejection. They are also electrically isolated from each other.
12.2.1 Logic Diagram
Channel A
Indication
LED "INA"
Inversion
TTL
13
Output
1
Optically Isolated
Digital Input TTL - RS485
2 19 RS485
20 Output
Channel B
Indication
LED "INB"
Inversion
TTL
15
Output
3
Optically Isolated
4 21 RS485
22 Output
Channel C
Indication
LED "INC"
Inversion
TTL
17
Output
5
Optically Isolated
6 23 RS485
Indication Output
LED 24
Channel D
Indication
LED "IND"
TTL - RS485
25 RS485
26 Output
7
Optically Isolated
Digital Input
8
Indication
High
LED "En" Speed
1A Switch
27 Ch D High Speed Output

9
28 +24V Output
Indication
LED "PWR"
UTIM 11 +24V Input

Internal
Power Supply 12 0V Input
12.2.2 Electrical Installation
Input D\
Input D
Input C\
Input C Enable Input (link to 0V to activate)
Input B 0V
Input B\
Input A\ +24V DC Supply Input
Input A 0V Supply Input
Output A (TTL) Output D (open collector)

0V +24V DC Output (300mA)
Output B (TTL)
0V Output D\ (RS485)
Output C (TTL) Output D (RS485)
0V Output C\ (RS485)
Output C (RS485)
Output B\ (RS485)
Output B (RS485)
Output A\ (RS485)
Output A (RS485)
12.2.3 Technical Specification
Parameter Min Typical Max Units

Supply voltage (VS) 12 24 30 V
Supply current Nominal (Inom) 30 mA
Supply current Inrush (IR) 1 A
Inputs A, B, C, D Voltage 12 24 30 VDC

Inputs A, B, C, D Current 8 10 15 mA
Enable Input Voltage 0 V
Enable Input Current 8 10 15 mA

TTL Outputs A, B, C Frequency 2 MHz
RS422 Outputs A, B, C, D Frequency 2 MHz
Open Collector Output D Frequency 2 MHz
Open Collector Output D Current 1 A
User +V supply current 300 mA
Propagation delay input > TTL out 650 ns
Propagation delay input > RS-485 out 650 ns
Propagation delay input > Open Collector out 650 ns
Operating temperature 0 40 °C
Weight 100 g
Dimensions 127 x 45 x 27 mm
12.2.4 Cable Specification

• All signal cables should be screened type
• Single core screened for singled-end signals (+V in signal, TTL out and open
collector out) and twisted pair screened for differential signals (RS485).
• RS485 signals, the screen of the cable should link the 0V on the UTIM to the 0V on
the drive.
• Maximum cable length for output signals should be 1metre.
• Maximum length for input signal (+24V) should be 50 metres.

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Part Number: 0460-0078

Copyright © 9 September 2004 Control Techniques Drives Ltd

2 Mechanical Installation ................................... 6

3 Electrical Installation ...................................... 8

4 Software Installation ..................................... 17

6 Functional Description ................................ 38

7 Parameter Descriptions ............................... 66

8 Error Handling / Trouble Shooting .............. 97

10 Quick Reference .......................................... 122

11 Documentation Reference .......................... 126

1.2 Application Overview

Flying Shear Solutions Software User Guide for Unidrive Classic 4

A couple of possible applications are:

5 Flying Shear Solutions Software User Guide for Unidrive Classic

2.1 Application Module & Unidrive

2.1.1 Application Module

Flying Shear Solutions Software User Guide for Unidrive Classic 6

7 Flying Shear Solutions Software User Guide for Unidrive Classic

+10V analog supply (Terminal 4)

Flying Shear Solutions Software User Guide for Unidrive Classic 8

3.2 Unidrive Power / Motor Connections

3.3 UTIM Signal Interface Unit

3.4 Connector Location

9 Flying Shear Solutions Software User Guide for Unidrive Classic

3.4.3 Small Option Module

Flying Shear Solutions Software User Guide for Unidrive Classic 10

3.5 Default Control Connections

11 Flying Shear Solutions Software User Guide for Unidrive Classic

Forward H/W Limit Switch

3.5.3 Hardwired Interface Connections

Shear Healthy Status Relay

Master / Line Control

Flying Shear Solutions Software User Guide for Unidrive Classic 12

3.5.5 Tool Control Connections

TTL Cable TTL Cable

TTL Out 8 8 24Volt 32

0Volts 31 9 A 10kohm shunt resistor is

13 Flying Shear Solutions Software User Guide for Unidrive Classic

3.5.6 Connecting to a remote device using RS485 Comms

Flying Shear Solutions Software User Guide for Unidrive Classic 14

I/O Point Description Destination Invert In / Out Select

Programmable Threshold Settings

15 Flying Shear Solutions Software User Guide for Unidrive Classic

3.7 Isolation and Suppression

Flying Shear Solutions Software User Guide for Unidrive Classic 16

UD70OS.SYS - UD70 Application module only

Parameter Description Parameter Notation

17 Flying Shear Solutions Software User Guide for Unidrive Classic

NOTE Drive Switching Frequency is set at either 4.5 or 9Khz.

5.2 Operating Modes

Flying Shear Solutions Software User Guide for Unidrive Classic 18

NOTE The Angled cut axis speed can be calculated from:

19 Flying Shear Solutions Software User Guide for Unidrive Classic

Distance is entered as units

0 = Undefined User units

5.3.1 Selecting suitable units

Here are some examples of the parameters:

Parameter Description Resolution Maximum Value