Version 2.0 Pub. date: 1/3/02 v11PID Web Tension Controller
INSTALLATION AND OPERATING INSTRUCTIONS
X-3000ce-UW
Table of Contents
1 General Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
2 Technical Data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82.1 X-3000ce-UW Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2.2 X-3000ce-UW Mechanical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
3 lnstallation and Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - 113.1 Mechanical Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
3.2 Electrical Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
3.3 Quick Setup Guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - 153.4 Startup and Adjustment. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
3.5 Basic Diagrams for Standard Application - - - - - - - - - - - - - - - - - - - - 22
3.6 Complete Wiring Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
3.7 Terminal Blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
3.8 Basic Wiring Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
3.9 Digital Input: Standard Functions - - - - - - - - - - - - - - - - - - - - - - - - - - 30
3.10 Analog Signals: Standard Functions - - - - - - - - - - - - - - - - - - - 46
3.11 Input and Output: Special Functions - - - - - - - - - - - - - - - - - - - - - - 47
3.12 Web Break - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48
3.13 Range Expander of X-3000-ce-UW - - - - - - - - - - - - - - - - - - - - - - - 50
3.14 Diameter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55
3.15 Operation of the Controller Menu - - - - - - - - - - - - - - - - - - - - - - - - - 59
3.16 Menu Tree Diagnostic - - - - - - - - - - - - - - - - - - - - - - - - - - 603.17 Menu Tree - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
3.18 Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
3.19 Hardware Adjustment and LEDs - - - - - - - - - - - - - - - - - - - - - - - - - 63
4 Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 644.1 Tension Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
4.2 Regulation Parameter, Gain, Ratio, P and D - - - - - - - - - - - - - - - - - 65
4.3 Tuning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
4.4 Customer Parameter Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
5 Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68
6 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70
1/3/02 3
1 General DescriptionThe Montalvo X-3000ce-UW PID analog controller provides precise automatic control of web tension. The progressive PID regulator automatically compensates for roll diameter. The X-3000ce-UW is used in a closed loop, of which the load cell roller and brake (or other tension-affecting device) are a part.
To properly set up and operate the X-3000ce-UW and to take advantage of all its available features, it is important to have a general understanding of the controller and its place in the tensioning system (please refer to the diagram on the following page). A typical pneumatic system is displayed; however, the same principles apply to any other closed-loop control system. The control outputs of 4 to 20 mA and 0 to 10 volts DC enable the X-3000ce-UW to interface with a variety of output devices to control web tensioning brakes, clutches, and motors.
Load Cell Function
Two load cells (also called transducers) are normally used. The signals from the load cells are summed together to indicate total web tension across the entire web. Each load cell contains two strain gauges connected in a series. The two load cells are connected so that the four strain gauges form a Wheatstone bridge configuration supplied with + 2.5 VDC. The web tension transfers a force to the load cell roll, changing the resistance values in the bridge. The resulting voltage change is amplified and calibrated to display actual web tension.
Converter Function
The I/P converts the 4 to 20 mA regulator output to a proportional 0 to 75 PSI (0 to 6 bar) to control the brake. Other converters may be used, depending on the application.
Brake Function
One or more brakes may be controlled, converting the pneumatic output pressure from the I/P into torque. This torque in turn changes the web tension.
Auto Mode Function (Closed Loop)
The operator sets the desired tension with the auto setpoint potentiometer. The controller compares actual tension to the auto setpoint, and adjusts output until the actual tension and setpoint are equal. Because the web itself is part of the feedback loop, the X-3000ce-UW can quickly compensate for speed and diameter changes, and for other factors that affect tension during the process.
1/3/02 5
1 General Description
Manual Mode Function (Open Loop)
The operator sets the desired brake pressure with the manual potentiometer. The web tension is still measured and displayed on the tension meter, but is not regulated in this mode. To maintain tension, the operator must make constant adjustments.
Load cell
I/P converter
X3000ce-UW controller
Montalvobrake
50
20 80
100%0MANUEL/ AUTO
TENSION OFF/ON
AUTOMANUEL
OUTPUT
50
20 80
100%0
Type: X3000-ce-UW SN: 3455Supplyvoltage: 115/230V 60/50HzSupplycurrent : <0.5A
PR035.dsf
Air filter
6 1/3/02
General Function and Standard Operation Cabinet Version
1. Manual setpoint Sets controller output at a constant level when the controller is in manual mode. (Manual setpoint on a 0 to 100% scale produces 0 to 100% output.)
2. Auto setpoint In auto mode, the controller automatically regulates output so that actual tension reaches the tension setpoint (appears on a scale of 0 to 100% on the meter).
3. Actual tension Displays actual tension on a scale of 0 to 100%.
4. Controller output meter Displays controller/regulator output on a scale of 0 to 100%.
5. Manual / Auto switch Switches between manual and auto mode.
6. Tension on/off switch Turns tension on and off. Output is zero when off.
7. Green power LED Indicates that power is on.
IL030.dsf
OPTION:-Cal. low/high
OUTPUT
50
20 80
100%0
50
20 80
100%0
MANUAL/ AUTO
TENSION OFF/ON
AUTOMANUAL50
20 80
100%0
3 4 5 6
1 2
OPTION:-Splice level
7
1/3/02 7
2 Technical Data
2 Technical Data
2.1 X-3000ce-UW ElectricalAC Input 115 or 230 VAC +10% (IEC TC77B WG3) 48 to 62 Hz
Fuse Size (fuse not installed by factory)115 V-160 mA T (slow-blowing type) Ø5 x 20 mm230 V-80 mA T (slow-blowing type) Ø5 x 20 mm (Both types are supplied)
Overvoltage Category II (IEC 664)2 kV in 1 minimum primary to secondary
Pollution Degree 2
Material Fire Classification 94V0
Maximum Power Consumption 12 VA
Maximum Fuse Input 10A
Noise Immunity EN 50082-2 industrial
Noise Emission EN 50081-1
Load Cell Supply ±2.5 VDC ±5%
Load Cell Input 0 to ±250m VDC
Zero Range (tare) 100% of load cell rating [max. 500mVDC (+/- 250 mVDC)]
Calibration Range Gain: 11 to 480
Temperature Range 0 to 50° C (32 to 122° F) operating-10 to 80° C (14 to 176° F) storage
Degree of Protection IP 54 / IP 10 for non-cabinet version
Regulator Outputs
0 to 10 VDCMaximum load - 5 mA4 - 20 mA / 0-20 mA RL = 0 to 1000Ω
Meter Outputs
0 to 100 µARO = 100 KΩ 0 to 10 VDCMaximum load - 5 mA
Analog Input Voltage 0 to 10 VDCRI = 100KΩ
Digital Input Voltage 15 to 30 VDCRI = 10KΩ
Digital Output Voltage24 VDC ±5%±15Imax for a digital output: 100mATotal Imax for all 4 outputs: 250mA (if internal power supply is used).
Standards Designed to meet UL 508 and EN 60204
8 1/3/02
2.2 X-3000ce-UW Mechanical
2.2 X-3000ce-UW MechanicalDimensions (L x W x H) (Cabinet version) 330 x 260 x 163 mm (12.99" x 10.24" x 6.42")
Weight (Cabinet version) 4.7 kgs (10.38 lbs.)
Dimensions L x W x H (non-cabinet version) 160 x 160 x 55 mm (6.3" x 6.3" x 2.36")
Weight (Non-cabinet version) 1 kg (2.2 lbs.)
Cabinet version Non-cabinet version
50
20 80
100%0
MANUAL AUTO
TENSION OFF/ON
AUTOM A N U A L
OUTPUT
50
20 80
100%0
Type: X3000-ce-UW SN: 3455Supply voltage: 115/230V 60/50HzSupply current: <0.5A
IL007.dsf
IL140.dsf
1
2
3
4 5
6
7
8
9 1
0 1
1 12
13
14
15 1
6 1
7 1
8 19
20
21
22 2
3 2 4
25
26
27 2
8 2
9
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9 40
41
4 2 4
3 4
4 4
5 46
47
48
49 5
0 51
52
53
54 5
5 56
57
58
R1 R2 R3 R4 R5 R6
Enter
-
+Back Space
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
XXXXXXXX 0%
PE
Type : X-XXXXce-XXVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000
230
115
L N
1/3/02 9
3 lnstallation and Setup
3 lnstallation and Setup3.1 Mechanical Installation
IL076.dsf
160 mm
160
mm
1
2
3
4 5
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8
9 1
0 1
1 12
13
14
1 5 1
6 1
7 1
8 19
20
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22 2
3 24
25
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27 2
8 2
9
30 3
1 3
2 3
3 34
35
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37 3
8 3
9 40
41
42 4
3 4
4 4
5 46
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49 5
0 51
52
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54 5
5 56
57
58
148
mm
120 mm
55 m
m
PEL N
R1 R2 R3 R4 R5 R6
Enter
-
+Back Space
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
PE
230
115 TENSION 0%
L N
Type : X-3000ce-UWVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000
10 m
m
1/3/02 11
3 lnstallation and Setup
3.1.1 Cabinet
The X-3000ce-UW controller cabinet should be mounted in a dry place, away from any source of heat. The mounting surface should be free of any excessive vibration. If possible, the controller should be mounted at eye level and in a location accessible to the operator. If used, mount the I/P converter or P-3000 as close to the brake as possible.
Enclosure with doors open
Note: Plastic latch to hold door open
18.00" (457)
8.25"(210)
10.23"(260)
11.81 (300)
12.99" (330)
6.43" (163) 0.39" (10)Space for mounting
bracket
6.82" (173)
50
20 80
100%0
MANUAL/ AUTO
TENSION OFF/ON
AUTOMANUAL
OUTPUT
50
20 80
100%0
Type: X3000-ce-UW SN: 3455Supplyvoltage: 115/230V 60/50HzSupplycurrent: <0.5A
IL009.dsf
Avoid mounting the controller cabinet close to drive controllers or any other equipment that produces large amounts of EMI.
12 1/3/02
3.1 Mechanical Installation
3.1.2 X-3000-ce-UW CabinetFigure 1 mount standard. For other mounting brackets, consult factory.
Fig. 1
18°18°
Fig. 2
20°
45°
Fig. 3 Fig. 4 IL037.dsf
Cutout dimensions: 320 x 250 mm
1/3/02 13
3 lnstallation and Setup
3.2 Electrical Installation
Warning: Electrical installation must be done by skilled personnel. Wiring must meet all applicable codes and standards.
Refer to appropriate wiring and terminal descriptions for external connections.
Be sure that the voltage selector on the regulator PCB is in the correct position for the voltage supplied.
Select the PCB fuse size according to the input voltage selected. The maximum external fuse on the input is 10 A.
Note: 0VDC and PE are internally connected.
Note: Double-check accuracy of all wiring connections before applying power to the controller. Damage caused by improper wiring is not covered under warranty.
EMC Requirements
Connect protective ground wire to terminal marked PE. Ground wires should be as short as possible. Connect PE, mounting plate, and cabinet to a common ground.
Use only shielded cable for all external connections. For analog signals, terminate shield at controller end; for digital signals, terminate shield at both ends. For cabinet versions, connect shield to the cabinet at the point where the cable enters, whether to a buss bar or to the connector housing. Keep the shield as short as possible (not to exceed 10 mm or 0.4 inches). For best results, clamp the uninsulated shield directly to the buss bar with the strain reliefs provided.
Keep signal cables away from supply cables or any wires that conduct high current. For best noise immunity, run signal cables close to the machine frame, mounting plates, or other grounded structures.
Safety InformationThe following safety symbols appear in this manual.
Caution Electrical HazardFailure to follow installation and setup instructions in this manual may result in equipment damage or personal injury.
Failure to follow wiring instructions in this manual may result in equipment damage, personal injury, or death.
14 1/3/02
3.3 Quick Setup Guide
3.3 Quick Setup Guide
3.3.1 Introduction
The controller system will typically include the following components:
• 1 X-3000-ce-UW• 1 I/P converter (MPC 3, 4, or 5)• 1 air filter (5 and 0.3 µm)• 2 load cells• 1 brake
Note: If the system includes other equipment, please refer to the appropriate sections of the manual.
3.3.2 Mechanical and Pneumatic Installation
1. Mechanical Installation
Mount all components on the machine.
Note: Place I/P converter close to brake so that tubing is as short as possible.
The Quick Setup Guide is intended to help get the system up and running in a short period of time.
To maximize system performance, please read the entire manual.
50
20 80
10 0%0
50
20 80
10 0%0
M A N UE L /
A U TO
T EN S IO N
O FF /O N
AU TOM A N UE L
O U TP U T
Typ e: X 300 0- ce -U W S N: 34 55
S up pl yv ol t ag e: 1 15 /2 30V 60 /5 0H z
S up pl yc urre nt : < 0. 5A
Air filter
Start and stop signal frommain cabinet
115/230 VacPower supply
Load Cell 1 Load Cell 2
Brake
6-8 Barmain airsupply
I/P Converter
PR002.dsf
1/3/02 15
3 lnstallation and Setup
2. Pneumatic Installation
Connect main air supply (1) to air filter (2), air filter to I/P-converter (3), and I/P converter to brake cylinders (4)(see diagram below).
Recommended: install an air pressure gauge (or manometer) in line with the brake if the gauge is not present on the I/P converter.
3.3.3 Electrical Installation
1. I/P Converter
Connect cable from X-3000ce-UW controller to I/P converter (see diagram below):
1
23
5u 0.3u
4
PR003.dsf
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2
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4 5
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8
9 1
0 1
1 12
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6 1
7 1
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22 2
3 24
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27 2
8 2
9
30 3
1 3
2 3
3 34
35
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37 3
8 3
9 40
41
42 4
3 4
4 4
5 46
47
48
49 5
0 51
52
53
54 5
5 56
57
58
R1 R2 R3 R4 R5 R6
Ente r
-
+Back Sp ace
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
PE
230
115 TENSION 0%
L N
Type : X-3000ce-UWVoltag e : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000
WD044.dsf
15
16 1
7
0V 4 - 20 mA
0 - 10VCable from controller to I/P Converter
Regulatedoutput:
I/P Converter
(+) (-)(PS)+24 V
*Connect if I/P converteruses a 24 VDC power supply.
0V
+24V
1 2
3
4
4 - 20 mA0V
Shield /Ground
*
16 1/3/02
3.3 Quick Setup Guide
2. Load Cells
Plug cable into load cell and connect cable to the X-3000ce-UW controller (see diagram below).
3. Connection of start/stop signal from machine main panel:
Note: For explanation of softstart, see Section 3.9.1, p. 30.
Connect cable between machine main panel and X-3000ce-UW. The signal must come from a relay with the following function:
a) The relay must:
• energize when machine starts running or moving• de-energize when stop is pressed or when machine comes to a complete
stop (zero speed signal).
b) From this relay use the opening function (NC). The relay contact must be closed at stop and open at start of operation (see Fig. 1):
R1 R2 R3 R4 R5 R6
En ter
-
+Ba ck S pace
D own
U p
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
1
2
3
4
5
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7
8
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10
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2 1
3 1
4 1
5 1
6 1
7 1
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45
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51 5
2 5
3 54
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L N PE
T ype : X/D -300 0Serial no : 960034Voltage : 115V/23 0V ACCurrent : <200 mA
220
110
30 3
1 3
2 3
3 3
4 3
5 3
6 3
7 3
8 3
9 40
41
42
43
11 1
2 1
3 1
4
11
12 1
3 1
4
40 41
42
43
0VDC +2.5V
-2.5V
*Red *White *Black
*Color code for Montalvo standard cable
Cable from load cell 1
*Red *White *Black
-2.5V
+2.5V +Input
Shield / Ground- Input Cable from
load cell 2
Shield / Ground
0VDC
WD029.dsf
K100
K100
+24V
DI5Softstart/
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4 5
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9 1
0
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9
K100
1 (COM)
2 (NC)
MACHINE START
Fig. 1START
WD012.dsf
STOP
1/3/02 17
3 lnstallation and Setup
4. Connection of supply voltage to the X-3000ce-UW controller
Connect cable between machine main panel and X-3000ce-UW controller.
Select a supply voltage (230/115 VAC) that is turned on when the power to the machine main panel is turned on. Then:
a) Turn off machine main panel.
b) Connect cable in the machine main panel.
c) Remove fuse from the fuse holder on the printed circuit board (PCB) if fuse is already installed.
d) Connect cable in the X-3000ce-UW (see diagram below).
e) Turn on machine main panel again.
f) Using voltmeter, check connection of terminal points L, N and PE before inserting fuse.
g) Turn machine off.
h) Insert correct fuse and turn machine on.
L N PE
L N PE
220
230
115
10 MM Max.
R1 R2 R3 R4 R5 R6
Enter
-
+Back Space
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
1
2
3
4 5
6
7
8
9 1
0 1
1 12
13
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15 1
6 1
7 1
8 19
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3 2
4 25
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27 2
8 29
44
45
46 4
7 4
8 4 9
50
51 5
2 5
3 5 4
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56 5
7 58
L N PE
Type : xxxxxxxxxxSerial no : xxxxxxxxVoltage : xxxxxxxxxCurrent : xxxxxxx
230
115
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9 40
41 4
2 4
3
11 1
2 13
14
Voltage Switch ( In 230 v Position )
Fuse Holder
FUSE SIZE:115V -160mA T (slow blowing type) Dia. 5 - 20 mm230V - 80 mA T (slow blowing type) Dia. 5- 20 mm
WD022.dsf
18 1/3/02
3.3 Quick Setup Guide
3.3.4 Web Tension Adjustment
1. Check that load cells are mounted and oriented properly. Refer to the load cell installation instructions.
2. Before applying power, check that tension meter is mechanically zeroed. If not, adjust the small screw below the meter scale until the meter reads zero.
3. Apply power to the controller and let it warm up for at least 10 minutes.
4. With web removed and no tension applied to the sensing roller, adjust potentiometer R1 until analog tension meter reads zero. (If non-cabinet version is used, see digital display: tension should read 0%.) If value is below zero, turn R1 clockwise; if above, turn counterclockwise.
Note: R1 and R2 are 25-turn potentiometers, so many rotations may be required.
5. Thread a rope over the center of the tension-sensing roller following the exact path of the web. Make sure the rope extends at least one roller before and one roller after the sensing roller. Make sure the rope does not pass over any dead bars or non-freewheeling rollers. Fasten one end of the rope securely.
6. Attach a weight of known value to the other end of the rope. For best results, the weight should be at least 25% of the analog meter's full-scale value. A tension value below 0% with the weight hung indicates that the signal from the load cells is reversed. In the event of such a reversal, switch wires 12 & 14 and 41 & 43 on the terminal block. To eliminate friction, rotate rollers in the direction of the weight.
For cabinet and non-cabinet versions of the controller, see section 2.2, p. 9.
MANUAL
MANUAL/ AUTO
AUTO
TENSIONOFF / ON
T
20 80
50
20 80
50
20
OUTPUT
IL004.dsf
R1 R2 R3 R4 R5 R6
+Back SpaceUp
DO 4DO 3DO 2DO 1
00
Load cell
IL005.dsf
1/3/02 19
3 lnstallation and Setup
7. Adjust potentiometer R2 until analog meter reading is identical to the hanging weight. (If non-cabinet version is used, see digital display: tension will appear as a percentage value [%]).
8. Remove weight and check that tension meter returns to zero. If not, repeat steps 4 to 7.
9. If a second calibration range is used, repeat steps 4 to 8, using potentiometer R3 for calibration of second range.
R1 R2 R3 R4 R5 R6
+Back SpaceUp
DO 4DO 3DO 2DO 1
00
Load cell KG
IL006.dsf
20 1/3/02
3.4 Startup and Adjustment.
3.4 Startup and Adjustment.
The system is now ready to start.
1. Scroll to the password menu. Press enter, then up arrow to change display to 5. Press enter again, then down arrow key. Password 5 allows access to setup menu.
2. Scroll to the parameter [Gain] under the setup menu.
3. Install a small roll on the unwind stand.
4. Run machine at low speed and adjust [Gain]until web tension is steady but still responsive to variations.
5. Stop machine and go to parameter [Ratio] under the setup menu.
6. Install a large roll in the unwind stand.
7. Run machine at low speed and adjust [Ratio] until web tension is steady but still responsive to variations.
8. Scroll to [Softs Menu] and adjust [Softs Time] so that it fits the machine's deceleration ramp.
• If signal for start/stop (terminal 34) goes low before machine reaches zero speed, enter time between maximum and zero speed in parameter [Softs Time].
• If signal to start/stop (terminal 34) goes low only when machine reaches zero speed, set time in parameter [Softs Time]to 0.2 seconds.
Note: The Quick Setup Guide is intended to get the system up and running in a short period of time. To maximize system performance, please read entire manual.
Note: For complete instructions on keypad use, see Section 3.15, p. 59.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
1/3/02 21
3 lnstallation and Setup
3.5 Basic Diagrams for Standard Application Non-cabinet Version
IL140.dsf
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2
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9 1
0 1
1 12
13
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15 1
6 1
7 1
8 19
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22 2
3 2 4
25
26
27 2
8 2
9
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9 40
41
4 2 4
3 4
4 4
5 46
47
48
49 5
0 51
52
53
54 5
5 56
57
58
R1 R2 R3 R4 R5 R6
Enter
-
+Back Space
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
XXXXXXXX 0%
PE
Type : X-XXXXce-XXVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000
230
115
L N
44 45 18 19 20 47 48 49
10 K
Autosetpoint
10 K
Manualsetpoint
V o lta g e0 - 10 V
TENSION output
46L N
Power supply115 / 230 VAC
34 36 6
Softstart Anticoast(Stop orzero speed)
(Fast stop)
- +
WD069.dsf
bla
ck
wh
ite
red
Loadcell1
Loadcell2
*Type 1 connector 3 pole MIL std. (a-c)*Type 2 connector 6 pole DIN std. (1-3)
bla
ck
wh
ite
red
1412 13
*a/1 *c/3*b/2 *a/1*c/3 *b/2
4143 42PE is connected to 0 VDC
31 33 32
Manual Tensionoff
Voltage0 - 10 V
- +
REGULATED output
15 16 17
4 - 20mACurrent
4
* * S e e
b e l o wn o t e
**Connect wire if converter uses24 VDC power supply
PE
22 1/3/02
3.5 Basic Diagrams for Standard Application
Cabinet Version
50
20 80
100%0
MANUAL AUTO
TENSION OFF/ON
AUTOM A N U A L
OUTPUT
50
20 80
100%0
Type: X3000-ce-UW SN: 3455Supply voltage: 115/230V 60/50HzSupply current: <0.5A
IL007.dsf
WD073.dsf
bla
ck
wh
ite
red
Loadcell1
Loadcell2
*Type 1 connector 3 pole MIL std. (a-c)*Type 2 connector 6 pole DIN std. (1-3)
bla
ck
wh
ite
red
1412 13
Multi cable
Multi connector
10 K
Manual
10 K
Autosetpoint
+10V
GN
D
+10V
GN
D TensionOff
GN
D
+10V
+24V
OutputTension
100 K
100 K
Front panel
4 517 19 12 13127 28 Multi connector
Manual
*a/1 *c/3*b/2 *a/1*c/3 *b/2
4143 42
34 36 6
Voltage0 - 10 V
- +
REGULATED output
15 16 17
4 - 20mACurrent
4
* * S e e
b e l o wn o t e
**Connect wire if converter uses24 VDC power supply
Softstart Anticoast(Stop orzero speed)
(Fast stop)
L N
Power supply115 / 230 VAC
PEPE is connected to 0 VDC
1/3/02 23
3 lnstallation and Setup
3.6 Complete Wiring Diagram
L N
Power supply115 / 230 Vac
Multi cable
main board
bla
ck
wh
ite
red
Loadcell1
Loadcell2
*Type 1 connector 3 pole MIL std. (a-c)*Type 2 connector 6 pole DIN std. (1-3)
bla
ck
wh
ite
red
1412 13
*a/1 *c/3*b/2 *a/1*c/3 *b/2
4143 42
44 45
Voltage0 - 10 V
Current0 - 100uA
TENSION OUTPUT
46100 K
Multi connector27 28 1917
PE is connected to 0VDCPE
OPTIONS
10 K
Manualsetpoint**
10 K
Auto
10 K
SpliceLevel*
+10V
GN
D
+10V
GN
D
+10V
GN
D
Manual**Tension Second
Cal.**
GN
D
+10V
+24V
OPTIONS
OutputTension
100 K
100 K
Front panel
4 517 19 23 12 13127 28 Multi connector 14
OPTIONS
10 K
Manual
10 K
Auto
10 K
SpliceLevel*
+10V
GN
D
+10V
GN
D
+10V
GN
D Tension SecondCal.**
GN
D
+10V
+24V
OPTIONS
OutputTension
100 K
100 K
Front panel
4 517 19 23 12 13127 28 Multi connector 14
OPTIONS
10 K
Manual
10 K
Autosetpoint**
10 K
SpliceLevel**
+10V
GN
D
+10V
GN
D
+10V
GN
D TensionOff**
SecondCal.**
GN
D
+10V
+24V
OPTIONS
OutputTension
100 K
100 K
Front panel
4 517 19 23 12 13127 28 Multi connector 14
47 48 49 18 19 20
10 K
Manualsetpoint*
10 K
Autosetpoint*
+10V
GN
D
+10V
GN
D
Y 1 .0 Y 1 .1 Y 1 .2
EMERGENCY STOP
RANGE 1 RANGE 2
I/P-Converter
7 9 39
E-Stoprelay
4300mA 100mA 100mA24VDC
16 1517
4 - 20mACurrent
Voltage0 - 10 V
REGULATED output***Connect wire if converter uses
24 VDC power supply
* * * S e en o t eb e lo w
1
2
3
4 5
6
7
8
9 1
0 1
1 12
13
14
15 1
6 1
7 1
8 19
20
21
22 2
3 24
25
26
27 2
8 2
9
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9 40
41
42 4
3 4
4 4
5 46
47
48
49 5
0 51
52
53
54 5
5 56
57
58
R1 R2 R3 R4 R5 R6
Enter
-
+Back Space
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
TENSION 0%
PE
Type : X3000ce-UWVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000
230
115
L N
WD005L.dsf
24 1/3/02
3.6 Complete Wiring Diagram
OPTIONS
Y 1 .3 Y 1 .4
RANGE 3 RANGE 4 or WEB BREAK
10 38
R e la y
50 51 52
10 K
SpliceLevel**
+10V
GN
D
31 332
Manual** TensionOff**
Secondcal.**
33
+24V
34 26
Anticoast Splice
36
Softstart(Stop orzero speed)
(Fast stop)
+24V
Proximity switches
OPTIONS
OPTIONS
5
+24 S 0V
3533 1
Web pulse Brake pulse
+24 S 0V
PNP PNP
** Analog signals (manual setpoint, auto setpoint and splice level) and digital signals (manual, tension off and second cal.) can only be used one place at the time. Signals used on the front panel cannot be used on the main board.
+24V
GN
D
24 25 27
10 K
input 0 - 10VdcAnalog diameter
GN
D
+10V
5553
Input 0-10VGain control
GN
D
5756
0-10VAnalog output 2
GN
D
2928
Output 4-20mA
GN
D
5856
Input 0-10V
GN
D
Volt
Amp.1223 13 14
100mA 100mA
50
20 80
100%0
50
20 80
100%0
MAN UEL/ AU TO
TE NSION OFF /ON
AUTOMAN UEL
OUTP UT
50
20 80
100%0
W D005R.dsf
1/3/02 25
3 lnstallation and Setup
3.7 Terminal Blocks
Note: jumpers that connect terminals 4 and 7 and 57 and 58, and that are shipped with the controller, do not appear in the diagram above.
1
2
3
4 5
6
7
8
9 1
0 1
1 1 2
13
14
15 1
6 1
7 1
8 19
20
21
22 2
3 24
25
26
27 2
8 2
9
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9 40
41
42 4
3 4
4 4
5 46
47
48
49 5
0 51
52
53
54 5
5 56
57
58
DI2 / SpliceDI4 / Sec. calibration+24VDI6 / Web Pulse DI8 / Anticoast+24V input for DO
DO2 / Range 1DO4 / Range 3
0VDC
Manual / DI1Tension OFF / DI3
+24V
+24V
Softstart / DI5Brake Pulse / DI7
Range 2 / DO3
-2.5V
-2.5V +2.5V
+2.5V
+Load cell input-Load cell input
+10V+10V
+10V
+10V-10V
Regulator output 4-20mARegulator output 0-10V
Tension output 0-10VTension output 0-100uA
Auto setpoint 0-10V
Taper setpoint 0-10VDiameter output calibrated 0-10V
Diameter/trim input +10V
4-20mA output from U/I converter Input for extra U/I converter 0-10 V
Extra analog output2 0-10V
External gain 0-10VSummation input 0-20V
Splice setpoint 0-10V
Manual setpoint 0-10V
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
Web break or Range 4 / DO1
WD014.dsf
26 1/3/02
3.8 Basic Wiring Instructions
3.8 Basic Wiring Instructions
3.8.1 Installation: Load Cell Connections
The following terminals are for load cell connections. The standard cable from Montalvo is supplied with a connector for the load cell. Wire the other end into the terminal block of the circuit board.
Terminal Connection
12 -2.5 V Supply
13 +Load Cell Input
14 +2.5 V Supply
41 +2.5 V Supply
42 -Load Cell Input
43 -2.5 V Supply
11 1
2 13
14
15 1
6 17
40 4
1 42
43
44
45 4
6
*GREEN
LOAD CELLCABLE
0VDC+2.5V
-2.5V-INPUT
*RED*WHITE*BLACK
0VDC-2.5V
+2.5V+INPUT
*Colors refer to standard cables supplied by Montalvo
LOAD CELL 1 CABLE
0VDC+2.5V
-2.5V-INPUT
*RED*WHITE*BLACK
LOAD CELL 2 CABLE
0VDC-2.5V
+2.5V+INPUT
Connection for T-Series Idler, Live Head & UPB
Connection for N-Series Load Cells
11
1 2 1
3 1
4 15
16
17
40 4
1 42
43
44
45 4
6
*RED*WHITE*BLACK LOAD CELL 1
CABLE
0VDC+2.5V
-2.5V-INPUT
0VDC-2.5V
+2.5V+INPUT
*Colors refer to standard cables supplied by Montalvo.
Connection for Ribbon Head
100 ohm resistor
100 ohm resistor
40 4
1 42
43
11 1
2 13
14
40 4
1 42
43
44
45 4
6
11 1
2 13
14
15 1
6 17
*RED*WHITE*BLACK
*Colors refer to standard cables supplied by Montalvo
PE
PE
PE
1
2
3
4 5
6
7
8
9 1
0 1
1 12
13
14
1 5 1
6 1
7 1
8 19
20
21
22 2
3 24
25
26
27 2
8 2
9
30 3
1 3
2 3
3 3 4
35
36
37 3
8 3
9 40
41
42 4
3 4
4 4
5 46
47
48
49 5
0 51
52
53
54 5
5 56
57
58
R1 R2 R3 R4 R5 R6
Ent er
-
+Back Space
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
TENSION 0%
PE
Type : X3000ce-UWVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000
230
115
L N
T-Series Idler Shaft T/er-Series Live Roller
UPB-Series
N-Series
R-Series
WD006.dsf
1/3/02 27
3 lnstallation and Setup
3.8.2 Installation: Regulated Output
15 0VDC Common signal (GND) for regulated voltage or current output. Connects to input ground of the converter.
16 Regulated Current Regulated 4–20 mA current signal to an I/P or other converter.
17 Regulated Voltage
Regulated 0–10 V output. Can be used for a 0–10V I/P or other converter. Can control motor drives operating in the torque mode. Maximum load: 5 mA.
4, 33, 36=24 V Supply Unregulated 22 to 28 volt DC supply for external use. Maximum load: 250 mA.
1, 8, 11, 15, 18, 21, 24, 28, 30, 37, 40, 44, 47, 50, 53, 56 = 0VDC
Common for signal (GND) and contact inputs and outputs
Wiring Diagram for I/P Converter and P-3000 (signal = 4-20 mA)
Wiring Diagram for I/P Converter and P-3000ce (signal=4-20 mA and 24 V supply)
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
15
16 1
7
0 V4 - 20 mA
0 - 10 VCable from controller to I/PConverter or P-3000
Regulatedoutput:
I/P ConverterP3000
Plug
WD045.dsf
Shield /Ground
1
2
3
4 5
6
7
8
9 1
0 1
1 12
13
14
15 1
6 1
7 1
8 19
20
21
22 2
3 24
25
26
27 2
8 2
9
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9 40
41 4
2 43
44
45
46 4
7 4
8 49
50
51 5
2 5
3 54
55
56 5
7 5
8
R1 R2 R3 R4 R5 R6
E nter
-
+Back Spa ce
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
XXXXXXX 0%
PE
Type : X-XXXXce-XXVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000
230
115
L N
0 V4 - 20 mA
(-) GND(+) Signal
15
16 1
7
0 V4 - 20 mA
0 - 10 VCable from controller to I/P Converter or P3000ce
Regulatedoutput:
I/P ConverterP3000ce
Plug
0 V
+24 V
1
2 3
4
Shield /Ground
1
2
3
4 5
6
7
8
9 1
0 1
1 12
13
14
15 1
6 1
7 1
8 19
20
21
22 2
3 24
25
26
27 2
8 2
9
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9 40
41
42 4
3 4
4 4
5 46
47
48
49 5
0 51
52
53
54 5
5 56
57
58
R1 R2 R3 R4 R5 R6
Enter
-
+Back Spa ce
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
XXXXXXX 0%
PE
Type : X-XXXXce-XXVoltage : 115 / 230 V ACCurrent : <200 mAS. nr . : 3000
230
115
L N
WD046.dsf
0 V4 - 20 mA
+24 V(-) GND
PS
(+) Signal
28 1/3/02
3.8 Basic Wiring Instructions
3.8.3 Connecting VAC Power Supply
The controller must be supplied with a 115/230 VAC power supply. Set the voltage selector switch in the right position. For actual voltage, be sure to plug in the correct fuse.
L Supply Voltage
N Supply Voltage
PE Ground
L N PE
L N PE
220
230
115
10 MM Max.
R1 R2 R3 R4 R5 R6
Enter
-
+Back Space
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
1
2
3
4 5
6
7
8
9 1
0 1
1 12
13
14
15 1
6 1
7 1
8 19
20
21
2 2 2
3 2
4 25
26
27 2
8 29
44
45
46 4
7 4
8 49
50
51 5
2 5
3 54
55
56 5
7 58
L N PE
Type : xxxxxxxxxxSerial no : xxxxxxxxVoltage : xxxxxxxxxCurrent : xxxxxxx
230
115
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9 40
41 4
2 4
3
11 1
2 13
14
Voltage Switch ( In 230 v Position )
Fuse Holder
FUSE SIZE:115V -160mA T (slow blowing type) Dia. 5 - 20 mm230V - 80 mA T (slow blowing type) Dia. 5- 20 mm
WD022.dsf
1/3/02 29
3 lnstallation and Setup
3.9 Digital Input: Standard Functions
3.9.1 Softstart (Terminal 34)
Softstart input has two purposes:
• To stop the regulator when the machine is not running (hold mode).• To give the machine a soft startup.
When machine is running and this input signal is activated, the output level will be stored. This level will then be used for [Hold Level]and for the next startup.
In HOLD MODE, output is at a constant [Hold Level].
To compensate for roll inertia at next startup, the output must be reduced with a percentage of the stored level (typically 15 to 25%).
Running Example:
Machine is stopping
When this input is activated by 24 VDC, the controller switches to STOP MODE.
In STOP MODE the controller is still regulating until the time [Softs Time] has run out.
Machine has ramped to stop
When time has run out, controller changes to HOLD MODE.
In HOLD MODE, controller is not regulating and the desired output is set to a constant level = [Hold Level].
([Hold Level]= Stored level +%).
Machine is starting
When input is deactivated by removing +24 VDC, output will change to softstart level ([Softs Lev.]) and the regulator will begin to regulate from that level.
([Softs Lev.] = Stored level -%).
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
30 1/3/02
3.9 Digital Input: Standard Functions
Cycles
SOFTS TIME
Run mode Stop mode
Speed
Time
Run mode
Machine
0 %
100 %
Controlleroutput
100 %
0 %Time
HOLDLEVEL
Fig. 1
Fig. 2
STOREDLEVEL
SOFTS LEV
Hold mode
SD006.dsf
1/3/02 31
3 lnstallation and Setup
Electrical WiringParameter Setting and Adjustment:
1. [Start Out] (Start out)
[Start Out] is the output level with which controller starts when tension is switched on. This output is applied in two instances: 1) after power-up and 2) at TENSION ON. The output level varies in direct proportion to the setpoint. (Output=[Start Out] x setpoint)
Note: Set [Password]to 5 to access [Setup] menu.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
START
STOP
K100
+24V
Softstart/D15
K100
1 (COM)
2 (NC)
MACHINE START
Fig. 2
K200
+24V
Softstart/D15
1
2
3
4 5
6
7
8
9 1
0
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9
K200
3 (COM)
4 (NO)
Zero speed signal from machine
MACHINESPEED ISZERO
Fig. 1
WD007.dsf
1
2
3
4 5
6
7
8
9 1
0
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9
K100
Fig. 1 (zero speed)
Fig. 2 (stop)
1010
S o ft t im e
R un m ode S top m ode
S p e e d
T im e
R u n m o de
M a c h in e
0 %
1 0 0 %F ig . 1
H o ld m o d e
S o ft t im e
SD003.dsf
32 1/3/02
3.9 Digital Input: Standard Functions
To set the correct value:
a) Install a roll with maximum diameter and set the tension setpoint at 50%.
b) Start machine and run at a slow speed. Note output level when tension has become steady.
c) Stop machine and multiply output level noted in step b) by two (1/50% setpoint) and enter its value for [Start Out]. (For example, if noted output level is 30, set up 60). Use increase or decrease keys to change[Start Out]value.
Note: To see the new output level after changing [Start Out] parameter, switch tension off, then on again.
2. [Softs Lev.](Soft start level)
When the[Soft start] signal goes low (0VDC), the output changes to a percentage (%) of the stored level. This percentage is set up in this parameter.
To set the correct level:
a) Start machine at slow speed and stop after about 30 seconds.
b) Start machine again
c) Note tension.
d) If tension rises too much, decrease [Softs Lev.]; if tension drops too much, increase [Softs Lev.].
e) If adjustment in d) has been made, return to step b).
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
OUTPUT
50
20 80
100%0
50
20 80
100%0
MANUAL/ AUTO
TENSION OFF/ON
AUTOMANUAL
Output levelTension Tension setpointIL011.dsf
1/3/02 33
3 lnstallation and Setup
3. [Softs Time] (Time delay to stop)
If a stop signal is used and there is a delay between the time that the stop signal has been activated and the time that the machine reaches zero speed, enter the time as follows.
To set the correct time:
a) Run machine at maximum speed.
b) Measure time from activation of stop to zero speed.
c) Enter this time + 0.2 seconds in this parameter.
Note: If this time is longer than 10 seconds, use a zero speed signal.
d) Enter a short time when using a zero speed signal: minimum value is 0.1 seconds
4. [Hold level] (Hold level)
When [Softstart] signal is set high (Active high = +24 VDC), the controller stores the output level, but continues to regulate until the [Softs Time] has run out. If the time is set to the minimum value of 0.1 seconds, the output will change to hold level after 0.1 seconds. (Hold level = stored level +%.) If a longer time is set up, the output will change after that time. In hold mode, the output is at a constant hold level.
To keep the roll in the same position in hold mode, the stored level is increased by [Hold level] to create a holding output.
Hold level = Stored level.
Example of the output level in hold mode:
Hold Mode Menu: Hold level 100% => Stored level Hold Mode Menu: Hold level 150% => Stored level + 50%
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
34 1/3/02
3.9 Digital Input: Standard Functions
3.9.2 Anti coast (Fast stop) (TERMINAL 6)
Use this signal if the machine has a fast stop function or if it stops with a short rampdown time.
To prevent a drop in tension, activate signal exactly when machine begins to ramp down (see Fig. 1). This will prevent a drop of tension during that time.
Fig. 2 below shows how tension will drop if this signal is not used.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
TENSIONLEVEL
100 %
-100 % Time
Fig. 2
ANTICOAST
TENSIONDROPS
Speed
Time
Run mode
Machine
0 %
100 %
Hold mode
Anti-coastmode
Fig. 1
SD022.dsf
1/3/02 35
3 lnstallation and Setup
Stop signal is activated
When input is activated by 24 VDC, output increases to a higher level and then starts to regulate again. The level is set by the anticoast level parameter.
Anticoast is factory-set to use Source = OUTPUT.
Possible sources for anticoast:
Examples for which diameter source is best when production:
• Requires large rolls and low tension• Uses a great variety of materials
Note: set up and adjust diameter parameters in the diameter menu.
Electrical Wiring
Here is a typical example of how to connect the fast stop.
[OUTPUT]
The torque required for fast stop is calculated internally by the controller from the setpoint and the output. The result is a calculated diameter that can be scaled by an adjustable factor that fits the machine's actual rampdown time.
[DIAMETER]In some applications, the correct diameter cannot be calculated from setpoint and output. In such instances, diameter should be chosen as source.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
START
STOP
K100
K100
+24V DI8 / Anticoast
1
2
3
4 5
6
7
8
9 1
0
3 0 3
1 3
2 3
3 34
35
36
37 3
8 3
9
K100
1 (COM)
2 (NC)
MACHINE START
(fast stop)
WD003.dsf
Stop signal10
Run mode Stop mode
Time
Run mode
SpeedMachine
0 %
100 %
Anticoast mode
SD005.dsf
36 1/3/02
3.9 Digital Input: Standard Functions
Parameter Setting and Adjustment
1. [Anti.Src.] (Anti Source)
The source for the anticoast must be set up under the following parameter:
2. [Anti Max] (Anticoast maximum level)
Set up the maximum necessary level for the torque at fast stop with this parameter. See graph below.
To set the correct value:
a) Install a large roll. Set tension setpoint at about 50%.
b) Start machine and run it at maximum speed.
c) When tension has stabilized for 10 seconds, stop the machine with the function that activates the fast stop signal.
d) Note the tension.
e) Decrease [Anti Max]if tension rises; increase if tension drops.
f) If the adjustment has been made in step e), return to step b).
[Anti.Src.=OUTPUT]
The torque required for fast stop is calculated internally by the controller, from the setpoint and the output. The result is a calculated diameter that can then be scaled by an adjustable factor that fits the actual rampdown time on the machine.
[Anti.Src.=DIA.]
The torque required for fast stop is calculated internally by the controller from the actual diameter. The actual diameter is then scaled by an adjustable factor that fits the actual rampdown time on the machine.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
Anti Max = 200% Anti Max = 100%
Anti Max = 50%
AnticoastTorque
Controlleroutput
100%
80%
60%
40%
20%
0%20% 40% 60% 80% 100%
Anticoast level (max.)
C&G001.dsf
1/3/02 37
3 lnstallation and Setup
3. [Anti Min] (Anticoast minimum level)
Set up the minimum necessary level for torque at fast stop with this parameter. See graph below.
To set the correct value:
a) Install a small roll and set tension setpoint at about 50%.
b) Start machine and run it at maximum speed.
c) When tension has stabilized for 10 seconds, stop the machine with the function that activates the fast stop signal.
d) Note the tension.
e) Decrease [Anti Min]if tension rises; increase if tension drops.
f) If the adjustment has been made in step e), return to step b).
Anti min = 20%
Anti min = 30%
Anti min = 0%
Controlleroutput
100%
80%
60%
40%
20%
0%20% 40% 60% 80% 100%
AnticoastTorque
Anticoast (min.) C&G002.dsf
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
38 1/3/02
3.9 Digital Input: Standard Functions
4. [Anti Slope] (Anticoast slope) This parameter sets up the right slope for the torque at fast stop. See graph below.
To set the correct value:
a) Install a roll approximately 33% in diameter and set tension setpoint at 50%.
b) Start machine and run it at maximum speed.
c) When tension has stabilized for 10 seconds, stop the machine with the function that activates the fast stop signal.
d) Note the tension.
e) Increase [Anti Slope] if tension rises; decrease if tension drops.
f) If adjustment has been made in e), return to step b).
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
Anti Slope 1.0
2.0
3.0
100%
80%
60%
40%
20%
0%20% 40% 60% 80% 100%
Controlleroutput
AnticoastTorque
Anticoast Slope C&G003.dsf
1/3/02 39
3 lnstallation and Setup
3.9.3 Splice (DI2) (TERMINAL 2)
This function controls the regulator in splice sequence. The following sequence diagram shows a flying splice:
1. New roll is ready and in splice position when operator activates splice sequence. (Typically, new roll will be accelerated up to web speed.)
2. Splice arm moves down; new roll is spliced onto running web.
3. Knife cuts web from the old roll.
4. Knife and splice arm retract. Splice is finished.
In a splice sequence, output level must change from the regulated output level on the old (or expiring) roll to a new output level on the new roll. The output level on the expiring roll will normally be low, while on the new roll the output will change to a much higher level.
If diameter of a new roll is about the same at every splice, the splice level will always be the same. If the diameter that is being spliced varies to a great degree, the splice level will also vary every time. In a standard application, the splice level is set in a software parameter fixed at the same level for every splice. As an option, the splice level can be set up either from an external signal or from a potentiometer on the front of the cabinet version. The option should be used in cases in which splice levels vary to a great degree.
Flying splice unwinder
Knife 1
3 4
2
SD008.dsf
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
50
20 80
100%0
50
20 80
100%0
MANUAL/ AUTO
TENSION OFF/ON
AUTOMANUAL50
20 80
100%0
OPTIONS: Splice level
IL012.dsf
40 1/3/02
3.9 Digital Input: Standard Functions
Electrical Wiring
Below is an example of a splice signal connection. Typically a knife signal is used.
Optional: wire external splice level according to Fig. 2, if needed.
In splice mode the regulator is held at a constant level [Splice Lev] for a time [Splice Time], and then starts regulating again from that level (see diagram below). Optional: A delay between the knife signal and the cutting of the web can be set up in the parameter [Splice Del], if required.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
SPLICE
DI2Splice
1
2
3
4 5
6
7
8
9 1
0
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9
KNIFESIGNAL
Fig. 1
VALVEKNIFE
K200
3 (COM)
4 (NO)
K200
+24V
10 K
+10V
0 V
Splice levelinput 0 - 10V
5051
52
Fig. 2
0 V
Splice levelinput 0 - 10V50
5152
OR
+
WD016.dsf
output
Time
Regulated
0 %
Tension
0 %
Fig. 1
Time
TensionSetpoint
Splice
Knife signal or
DI2Splice /10
10splice button
TimeSpliceDelay Splice
Level
SD014.dsf
1/3/02 41
3 lnstallation and Setup
Parameter Setting and Adjustment
1. [Splice Src] (Splice source)
Set up the source for the splice level.
Note: splice level from the front of the cabinet and external splice level cannot be used at the same time.
2. [Splice Del] (Splice delay)
In the event of delay from activation of the knife signal to the cutting of the web, this time can be set up within this parameter.
3. [Splice Lev](Level from splice menu parameter)
[Splice Src = S. Lev]
The level for the splice is set up in the menu parameter for [Splice Lev]. A new output level is needed when the knife cuts the web. The new output level depends upon the diameter of the new roll. New rolls will typically be about the same diameter, in which case the level can be constant. To compensate for different setpoints, this output level varies in proportion to the setpoint. (Output = Splice Levx setpoint)
[NONE] Set up if splice is not used.
[S. Lev]
(Splice level is source.) With[S. Lev]as the source, the splice level is set up in a menu parameter. Choose this source if the diameter of the new roll is about the same at every splice.
[ANALOG]
(Analog source) With [ANALOG] as source, the splice level comes from an analog signal (0-10V). The analog signal can either be wired on terminal 51, or come from a potentiometer on the front panel in the cabinet version (see drawing below). Choose this source for large changes in the diameter of the new roll.
X-300010
K
+10V
Splice level 0-10V
0 V
Splice levelinput 0 - 10V
5051
52
+10V
10 K
0 V
boardMain
X-3000
boardFront panel
1.6 1.3 1.1
Operator&
controlpanel
50
20 80
100%0
50
20 80
1 00%0
MANUEL/ AUTO
TENSION OFF/ON
AUTOMANUEL
OUTPUT
Type: X3 000 -ce-UW SN: 34 55
Supplyvoltage: 1 15/230V 60/50 HzSupplycurre nt: < 0.5A
50
20 8 0
100 %0
WD042.dsf
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
42 1/3/02
3.9 Digital Input: Standard Functions
See this example with the [S. Lev] parameter set to 75%.
• Setpoint at 100% will give 75% output.• Setpoint at 50% will give 37.5% output.• Setpoint at 10% will give 7.5% output.
To set the correct value:
a) Install a roll with maximum diameter and set tension setpoint at 50%.
b) Start machine at slow speed. Note output level when tension has stabilized.
c) Stop machine and multiply the noted output level by 2 (1/50% setpoint) and set [Splice Lev] to that value. (For example, if noted output level is 30%, set up 60% in this parameter).
4. Level from analog source
To get a perfect splice, record splice level, diameter, and tension. To find the right values:
a) Install a full roll with the required tension setpoint.
b) Start machine at a slow speed. Note output level when tension has stabilized.
c) Stop machine and write down diameter, tension, and output level. The noted output level should be the correct splice level for this diameter.
d) Perform steps a - c with different diameters and tension setpoints and list them as well.
[Splice Src = ANALOG](Analog Source)
The signal on terminal 51 can either come from the front of the cabinet version or from an analog input signal. 0 to10 VDC on this analog input will give 0 to 100% output. Once the knife cuts the web, a new output level will be needed. The new output level depends upon the diameter of the new roll.
Production: Tension setpoint: Splice level: Diameter:Paper (40 grams/25 lbs.) 35% 60% 100%
Paper (40 grams/25 lbs.) 35% 45% 75%
Paper (40 grams/25 lbs.) 35% 30% 50%
Paper (80 grams/50 lbs.) 60% 80% 100%
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
OUTPUT
50
20 80
100%0
50
20 80
100%0
MANUAL/ AUTO
TENSION OFF/ON
AUTOMANUAL
Output levelTension Tension setpointIL011.dsf
1/3/02 43
3 lnstallation and Setup
5. [Splice Tim] (Splice time)
During this time, output is set to a constant level before returning to automatic regulation. Typical setting for this parameter is about 1.0 seconds.
Checking Splice Settings:
a) Put a new roll in splice position.
b) Run machine at splice speed, and make a splice. Tension should resemble that represented in Fig. 2.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
1
SD009.dsf
32
SD010.dsf
output
Time
Regulated
Tension
Fig. 2
Time
TensionSetpoint
Splice time Splice
level
Fig. 1
SD015.dsf
44 1/3/02
3.9 Digital Input: Standard Functions
3.9.4 Manual (DI1) (TERMINAL 31)
When activated by a 24 VDC input, the controller switches to manual mode. Regulated output is set by the potentiometer marked MANUAL. When deactivated, the controller regulates from the manual value.
3.9.5 Tension Off (DI3) (TERMINAL 32)
When activated by a 24 VDC input, the output goes to zero and the regulator is reset. This function is used at roll change. When input goes low, the regulator is set to the new roll parameter. (Start Out)
3.9.6 Second Calibration (DI4) (TERMINAL 3) (Option)
When activated by a 24 VDC input, the second tension calibration range must be used. Potentiometer R3 adjusts calibration for this range. Use this feature either for operation over a wide tension range or for two different web paths.
Sec. Calibration (DI4)
1
2
3
4 5
6
7
8
9 1
0
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9
Sec.cal.
+24V
WD152.dsf
1/3/02 45
3 lnstallation and Setup
3.10 Analog Signals: Standard Functions
Manual Potentiometers
47 0VDC Connects to the CCW terminal (1) of the MANUAL potentiometer. Use 10 kΩ potentiometer.
48 Manual 0 to 10 volt input corresponding from zero to maximum output in manual mode. Connects to the wiper terminal (2) of the MANUAL potentiometer.
49 10V Reference Reference voltage applied to the CW terminal (3) of the manual potentiometer. Total maximum load: 5 mA.
Auto Setpoint Potentiometer
18 0VDC Connects to the CCW terminal (1) of the AUTO potentiometer. Use 10 kΩ potentiometer.
19 Auto setpoint 0 to 10 volt input corresponding from zero to full scale tension in AUTO mode. Connects to the wiper terminal (2) of the AUTO potentiometer.
20 10V Reference Reference voltage applied to the CW terminal of the AUTO potentiometer. Total maximum load: 5 mA.
Splice Potentiometers
50 0VDC Connects to the CCW terminal (1) of the splice level potentiometer. Use 10 kΩ potentiometer.
51 Splice level Input for external signal if used to set output during splice mode. A 0 to 10 volt input corresponds from zero to maximum output.
52 10V Reference Reference voltage applied to CW terminal (3) of the splice level potentiometer. Total maximum load: 5 mA.
Tension Outputs44 VDC Common for tension outputs.
45 Tension 0 to 10V 0 to 10 volt output proportional to 0 to full-scale tension.
46 Tension 0 to 100µA 0 to 100 µA output proportional to 0 to full-scale tension.
15 1
6 1
7 1
8 19
20
21
22 2
3
44 4
5 46
47
48
49 5
0 51
52
+10V+10V
+10V
Regulator output 4-20mARegulator output 0-10V
Auto setpoint 0-10V
Splice Level 0-10V
Manual setpoint 0-10V
0VDC
0VDC 0VDC
0VDC
1
2
3
4 5
6
7
8
9 1
0 1
1 12
13
14
15 1
6 1
7 1
8 19
20
21
2 2 2
3 24
25
26
2 7 2
8 2
9
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9 40
41
42 4
3 4
4 4
5 46
47
48
49 5
0 51
52
53
54 5
5 5 6
57
58
R1 R2 R3 R4 R5 R6
Enter
-
+Back Space
Down
Up
DO 4DO 3DO 2DO 1
DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1
00
XXXXXXXX 0%
PE
Type : X-XXXXce-XXVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000
230
115
L N
WD076.dsf
0VDC Tension 0 to 10V
Tension 0 to 100µA
46 1/3/02
3.11 Input and Output: Special Functions
3.11 Input and Output: Special FunctionsSpecial Functions
58 Input 0-10V for Current Converter Input for voltage to current converter. Converts 0-10V into 0-20mA/ 4-20mA, depending on setup.
57 Extra Analog Output2 +10V max 5mA. Used in special applications.
56 0VDC For extra analog output.
55 External Gain Input for external gain reference to the regulator. May be input from diameter calculator or other source. For special applications.
54 Summation
Extra summing input to regulator circuit (0-20 VDC). Used in intermediate applications where the tachometer signal is connected into the system. The signal must be galvanically isolated. For intermediate and special applications only.
29 Output 0-20mA/4-20mA Output from voltage to current converter. Converts 0-10V on terminal 58 into 0-20mA / 4-20mA, depending on setup.
26 -10 V Reference Reference supply for external use. -10V max 5mA.
Digital Inputs
35 Digital Input 6 24 VDC digital input from proximity switch or encoder on brake for diameter calculation. Maximum frequency 80 Hz.
5 Digital Input 5 24 VDC digital input from proximity switch or encoder on main machine for diameter calculation. Maximum frequency 800 Hz.
Digital Outputs7 Supply 24 VDC supply input for supply of digital outputs.
8 0VDC Common for digital output 1 & 2.
38 Digital Output 1 (web break) Digital output 24 VDC maximum 100mA. (Can also be used for range expander)
9 Digital Output 2 Digital output 24 VDC maximum 100mA. Normally used for range expander.
37 0VDC Common for digital output 3 & 4.
39 Digital Output 3 Digital output 24 VDC maximum 100mA. Normally used for range expander.
10 Digital Output 4 Digital output 24VDC maximum 100mA. Normally used for range expander.
1/3/02 47
3 lnstallation and Setup
3.12 Web Break
This digital output stops the machine if the web breaks. The output will typically activate a customer-supplied relay that stops the machine (maximum 100 mA load for the digital output).
The web break function is activated 10 seconds after softstart is low:
• (Softstart low = machine started).
This 10-second period allows startup with new rolls when little or no tension is present.
When web break is active, and tension goes below web break level longer than web break time, output will be activated (i.e., go high). See Fig. 1.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
Time untilWeb break function is active
Speed
Time
Machine
0 %
Tension
0 %
Fig. 1
Web break time
Time
TensionSetpoint
Web breakLevel
Softstart / DI5
DO1Web break / 10
10
web breakis active
10 sec.
SD007.dsf
48 1/3/02
3.12 Web Break
Electrical Wiring
Provided below is a typical example of the web break connection.
Parameter Setting and Adjustment
To set parameters in the web break menu, scroll to web break menu under the setup menu:
1. [Webbr Lev] (Web break level)
Tension under this level will activate output after the web break time.
The factory setting of 5% applies to most applications.
2. [Webbr. Time] (Web break time)
This is the time that the tension has to be under the web break level before output is activated (goes high).
To adjust this parameter, the time should be:
• long enough to prevent small tension drops stopping the machine.• short enough to prevent minimum material waste before stop.
START
STOPDO1Web break /
1
2
3
4 5
6
7
8
9 1
0
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9
K100
1 (COM)
2 (NC)
MACHINE START
Fig. 1
K100 24Vdc
WD017.dsf
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
1/3/02 49
3 lnstallation and Setup
3.13 Range Expander of X-3000-ce-UW
Range expansion divides the torque capabilities of a braking system into multiple ranges. Only ranges required for a desired torque are active at any given time. This feature allows a braking system to run a much wider scope of materials and tension settings. Each combination uses the braking system to its maximum potential and efficiency.
With a normal braking system, each brake pad is connected in parallel to regulated air output. The pads may be divided into groups called ranges using the range expander, which requires a P-3000 RE Pneumatic Interface. There can be anywhere between 2 and 4 ranges. Each range is driven from a separate valve switch in the P-3000. Using this method, only the ranges required for adequate torque within the linear range of brake functionality are active. The range expander will automatically switch in the number of ranges that are required and raise or reduce pressure on the brake accordingly. This will maintain the same tension across ranges.
Possible applications include:
The range expander can operate by two possible modes, by output or by diameter:
Changing Ranges by Tracking Output Pressure
Output Mode. The range expander will change to a lower range when output pressure regulates below 20% [Dn Level] for more than 20 seconds (range time) or to a higher range when output pressure regulates over 80% [Up Level] for more
Large Web Tension Variance small rolls/light material through large rolls/heavy material on same machine.
Fast Stop With High Inertia Rolls large rolls with low tension
Standard vs. range expander brake system
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake MenuPads R1Pads R2Pads R3Pads R4Randomize
Range Dia Menu4->3 Dia3->2 Dia2->1 Dia
Dia. MenuDiamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
Range Expander
Brake
P-3000 I/P Converteror
PR ES SU RE
PR005.dsf
50 1/3/02
3.13 Range Expander of X-3000-ce-UW
than 20 seconds (range time). During a range shift, the pressure is changed outautomatically to keep the same torque on the brake.
Changing Ranges by Tracking Diameter
Diameter Mode. The range expander will change to a lower range when the roll diameter is smaller than the switching diameter, or change to a higher range shift-up when roll diameter is greater than switching diameter. The controller automatically calculates the best switching diameters based on brake geometry. During a range shift, the pressure is changed automatically to keep the same torque on the brake.
Illustration of diameter, range, and pressure changes during typical unwind cycle under output pressure control
Illustration of diameter, range, and pressure changes during typical unwind cycle under diameter control
0
10
20
30
40
Range 4-3( 133%)
Range 3-2( 150% )
Range 2-1( 200% )
Output pressure
Time
Range time
DN level (20%)
Range Range time
100%
0%
time
SD016.dsf
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake MenuPads R1Pads R2Pads R3Pads R4Randomize
Range Dia Menu4->3 Dia3->2 Dia2->1 Dia
Dia. MenuDiamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
SD017.dsf
0102030
40
Range 4-3( 133%)
Range 3-2( 150% )
Range 2-1( 200% )
Output pressure
Time
0
7991
100
Diameter (%)
63
Time
506070
Range time
1/3/02 51
3 lnstallation and Setup
Electrical Wiring
Without Emergency Stop
With Emergency Stop
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake MenuPads R1Pads R2Pads R3Pads R4Randomize
Range Dia Menu4->3 Dia3->2 Dia2->1 Dia
Dia. MenuDiamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
Y5 Y1 Y2 Y3 Y4
EMERGENCY STOP
RANGE 1 RANGE 2 RANGE 3 RANGE 4
GND
WD010.dsf
3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9
1 2 3 4 5 6 7 8 9 1 0
3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9
1 2 3 4 5 6 7 8 9 1 0
Y5 Y1 Y2 Y3 Y4
EMERGENCY STOP
RANGE 1 RANGE 2 RANGE 3 RANGE 4
GND
K13 (COM)
4 (NO)EMERGENCY STOP
K1
EMERGENCY STOP RELAY
EMERGENCY STOP
WD009.dsf
52 1/3/02
3.13 Range Expander of X-3000-ce-UW
Pneumatic Diagram
Parameter Setting and Adjustment
To set up parameters in the range expander menu, go to range expansion [Range Exp.] under the setup menu and do the following:
1. [RE Source] (range expander source)
Select one of three modes of operation for the range expander:
Note: The factory recommends the following setup:
• X-3000-ce-UW= [OUTPUT] or [DIA.]• D-3000-ce-UW=[DIA.]
Note: All remaining range expansion parameters must be set in Tension off mode.
2. [Ranges]
Select the number of ranges in your system: 2, 3 or 4.
3. [Start No.]
Select the starting range number: 1, 2, 3 or 4.
This is the range used after a range expander reset, which occurs after the following three conditions:
• Power has been applied to the controller• Tension has been switched on (new roll)• Controller has performed a splice operation.
Typical pneumatic connection
[NONE] Range expander not used
[DIA] Range expander runs under diameter control
[OUTPUT] Range expander runs under output pressure control
1 Air supply, 6-8 bar
2 Air filter
3 I/P converter, 0-6 Bar
4 Emergency stop valve
5 Manometer
6 Range 1 valve
7 Range 2 valve
8 Range 3 valve
9 Range 4 valve
1
2
3
45
6 7 8 9
Y1 Y2 Y3 Y4
Y5
Brake
5u 0.3u
PR006.dsf
1/3/02 53
3 lnstallation and Setup
Recommended: choose this value to reflect most frequently used material and roll diameter.
4. [Dn Level]when[RE source = OUTPUT]
If output level is below the [Dn Level] longer than [Range Time], the controller will switch down one range.
5. [Up Level]when[RE source = OUTPUT]
If output level is over the [Up Level] longer than [Range Time], the controller will switch up one Range.
6. [Range Time]
This is the delay time before the controller switches one of the ranges in or out. Following criteria will start the time delay:
[RE source = OUTPUT]
a) If output is under [Dn Level],[RE source = OUTPUT]
b) If output is over [Up Level][RE source=OUTPUT].
c) If a diameter switch-point is reached, [RE source=DIA] .
Note: In all conditions, controller must run in Auto mode before switching.
7. Enter [Brake Menu] sub-menu
For example: If [Ranges] = 2, only [Pads 1] and [Pads 2] should be set.
a) [Randomize YES] or [Randomize NO]
For equal wear of brake pads, randomize starting range.
If [Randomize YES] is selected, controller will rotate among the lowest ranges with equal numbers of brake pads. (Range 1 is the lowest range, Range 4 the highest.)
8. [Range Dia Menu]when (Re Source=DIA)
Note: This is only a readout parameter.
[Pads 1] [Pads 2] [Pads 3] [Pads 4]*
The number of brake pads in each of the possible ranges. You do not need to set values for ranges that are > [Ranges].
[4/3 Dia][3/2 Dia][2/1 Dia]
The best diameter switch points for the controller. The switch points are calculated from the information set up in the brake menu.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake MenuPads R1Pads R2Pads R3Pads R4Randomize
Range Dia Menu4->3 Dia3->2 Dia2->1 Dia
Dia. MenuDiamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
54 1/3/02
3.14 Diameter
3.14 Diameter
The diameter is in some cases useful and necessary, such as in the following instances:
• Control of gain• Reduction of tension (taper) on rewinder• Control of stop level at fast stop• Control of range expander in some special versions
The diameter can be calculated in 3 different ways:
1. Diameter Calculated From Tension and Output [LOCAL]
A function most often used in standard load cell applications. The diameter calculated is approximate, and not useful in applications requiring precise diameters.
2. Diameter Calculated From 2 Proximity Switches [PULSE]
The roll diameter is calculated during running by 2 proximity switches, one that senses roll revolutions (location 1) and the other that senses web speed (locations 2, 3 or 4). At the startup after roll change, the diameter of the new roll is calculated when the controller has received 2 pulses from the new roll. Pulse diameter calculations are recommended for machines with a wide web tension range; these calculations also improve fast stop function.
[LOCAL]The processor calculates a diameter from the tension and output. This way will not work in applications requiring a wide web tension range.
[PULSE] Diameter calculated from two digital input signals (2 proximity switches).
[ANALOG] Diameter from an external analog input signal.
Calculation of roll diameter
SD011.dsf
Brake
1. Brake pulse 2. Web pulse 3. Web pulse
4. Web pulse
1/3/02 55
3 lnstallation and Setup
a) Brake Pulse (Terminal 35)
A proximity switch that pulses 1 to 4 times per revolution during rotation of the roll is mounted on the unwind. It is best mounted where you can sense a keyway, screw, or bored hole in the shaft; other possible sensing locations are the safety chucks and the brake.
Note: Maximum input frequency must not exceed 80Hz.
b) Web Pulse (Terminal 5)
A proximity switch is mounted to sense the web length/pulse. The proximity switch can be installed in position 2, 3 or 4. The recommended web length/pulse is between 10 and 250 mm/pulse. For better resolution, use short distances between pulses.
Note: Maximum input frequency must not exceed 800Hz.
3. Diameter From External Analog Input [ANALOG]
An external analog signal can also be used. The signal must be a 0-10 VDC signal = 0-100% diameter. However, any signal between 2-6 VDC or 4-9 VDC can still be used because it is connected to a circuit with zero and span adjustments, after which the signal goes to the microprocessor. See the following diagram:
Warning: Do not place the proximity switch where it will be overheated by the brake.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Pads R1Pads R2Pads R3Pads R4Randomize
Range Dia Menu4->3 Dia3->2 Dia2->1 Dia
Dia. MenuDiamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
+10VX1.27
X1.25
X1.24Diameter input
++
+-ZERO
R4
R5 Span.
X1.23
Diameterinput AI6to micro-processor
Diameter calibrated
0VDC
WD021.dsf
56 1/3/02
3.14 Diameter
Electrical Wiring
Figures 1 and 2 describe the proper connection of the analog diameter signal and the 2 proximity switches:
Parameter Setting and Adjustment
To set up parameters in the diameter menu, go to diameter menu[Dia. Menu]in setup menu and do the following:
1. [Diamet Src] (Diameter source)
Select one of three modes for diameter.
a) If [LOCAL]is source, set up the following parameters:
1) Install a roll and measure its diameter (0-100%).2) Go to parameter “Diameter factor auto setup” [DF Auto set].3) Run machine at low speed until tension has stabilized for 10 seconds.4) Input actual diameter; press [Enter]. When [Enter] is pressed,
factor for the diameter will be calculated.
[LOCAL]The processor calculates the diameter from output and tension. (Factory setup)
[PULSE] Diameter is calculated from 2 proximity switches.
[ANALOG] Diameter from an analog input signal.
[Min Diam] (Minimum diameter). Minimum roll size must be set up in percentages (0 - 100%).
[Max Diam] (Maximum diameter). Maximum roll size must be set up in percentages (0 - 100%).
10 K
+10V
0 V
Diameterinput 0 - 10V
2425
27
Fig. 1
0 V
Diameterinput 0 - 10V
2425
27OR
+
1
2
3
4 5
6
7
8
9 1
0
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9Fig. 2
Proximity switches
+24V
+24 S 0V
Web pulse Brake pulse
+24 S 0V
PNP PNP
GND
WD020.dsf
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Pads R1Pads R2Pads R3Pads R4Randomize
Range Dia Menu4->3 Dia3->2 Dia2->1 Dia
Dia. MenuDiamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
1/3/02 57
3 lnstallation and Setup
b) If [PULSE] is source, set up the following parameters:
c) If [ANALOG] is source, set up the following parameters:
1) Go to parameter [Diameter].2) Enter analog value for minimum diameter and adjust on potentiometer
R4 until 0% is displayed.
3) Enter analog value for maximum diameter and adjust on potentiometer R5 until 100% is displayed.
2. [New Roll D](New Roll Diameter)
New Roll Diameter is the diameter to which, after roll change, the controller is set until the calculation of the correct diameter by running again. The New Roll Diameter is automatically set to the maximum diameter when a new maximum diameter is entered. If application does not require maximum diameter, the parameter can be adjusted.
3. [Diameter](Diameter)
The current calculated diameter based upon previously set parameters.
[P/rev Roll] The number of pulses per revolution on the roll.
[mm/Pulse] Mm between pulses on the main machine.
[Min Diam] Minimum roll size in mm.
[Max Diam] Maximum roll size in mm.
[Min Diam] Minimum roll size in percentages (0 - 100%).
[Max Diam] Maximum roll size in percentages (0 - 100%).
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
R1 R2 R3 R4 R5 R6
+Back SpaceUp
DO 4DO 3DO 2DO 1
00
IL014.dsf
R1 R2 R3 R4 R5 R6
+Back SpaceUp
DO 4DO 3DO 2DO 1
00
IL015.dsf
58 1/3/02
3.15 Operation of the Controller Menu
3.15 Operation of the Controller Menu
The controller operates in two modes:
• Scroll Mode • Edit Mode (the cursor blinks)
And has three types of menu items:
• submenu• numeric parameter• textual parameter
Menus are arranged in a hierarchical tree structure. The controller starts in scroll mode. A submenu is any menu below the current menu. A parent menu is any menu above the current menu.
Example: in the following instance, the user increases the value of [Softs Time] to 3.0 seconds. With the controller displaying [Diagnostic], the required steps are as follows:
a) Press Down (↓) until [Setup Menu] appears on the display. Press Enter (↵) to enter the submenu.
b) Press Down (↓) until[Softs Menu]appears on the display. Press Enter (↵) to enter the submenu.
c) Press Down (↓) until [Softs Time] appears. Press Enter (↵) to edit the parameter. (The cursor will blink.)
d) Press Up or Down [↑↓] until 3.0 appears on the display.
e) Press Enter (↵) to store change.
Scroll Mode
Up↑: Move to previous menu item.
Down↓: Move to next menu item.
Back Space←: Move to parent menu.
Enter↵: Enter menu if a submenu, or change to edit mode if a numeric or textual parameter.
Edit Mode Up ↑ : Increase numeric parameter value or move to previous textual parameter value.
Down ↓: Decrease numeric parameter value or move to next textual parameter value.
Back Space←: Cancel edit, returning to previous value.*
Enter↵: Store edit and return to scroll mode.
*Note: Back Space does not apply to "live" edit parameters. In a live edit parameter, the value is automatically stored when a change is made: the previous value cannot be returned to.
Enter
-
+Back Space
Down
Up
Enter
-
+Back Space
Down
Up
↓Diagnostic↓Password↵Setup Menu
↵Softs Menu
↓Start Out↓Softs Lev.↵Softs Time
[↑↓] ↵
1/3/02 59
3 lnstallation and Setup
3.16 Menu Tree DiagnosticMain menu Submenu DescriptionDIAGNOSTIC Main menu
VERSION Software version
RUN MODE Shows the actual Run Mode
TENSION Analog input no. 2, tension -110% to 110%
SETPOINT Analog input no. 1, setpoint-110% to 110%
OUTPUT Analog input no. 8, output - 110% to 110%
I-LEVEL Analog input no. 3, integrator -110% to 110%
MANUAL Analog input no. 4, manual level -110% to 110%
SPLICE Analog input no. 5, splice level -110% to 110%
SUMMATION Analog input no. 7, summing input 0 to 110%
GAIN Potentiometer level 0-63 steps
RATIO Potentiometer level 0-63 steps
DIAMETER Calculated diameter 0 -100%
ANALOG OUT2 Shows level on the extra analog output
PASSWORD Password gives access to setup and factory menus. To enter SETUP menu, use password 5
60 1/3/02
3.17 Menu Tree
3.17 Menu Tree
Please note that not all menus appear all of the time. Menus either irrelevant to the mode to without the correct password will not appear
DiagnosticVersionRun ModeTensionSetpointOutputI-LevelManualSpliceSummationGainRatioDiameterOutput2
PasswordSetup Menu(access with Pass-word 5)
Mode MenuRun ModeAmplifier0/4mA
LanguageGainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Time
WebBr MenuWebbr Lev.Webbr Time
Range exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu Pads 1 Pads 2 Pads 3 Pads 4 Randomize
Range Dia Menu 4->3 Dia 3->2 Dia 2->1 Dia
Dia. MenuDiamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
1/3/02 61
3 lnstallation and Setup
3.18 Setup Menu
Main Menu Submenu 1 Submenu 2 Description Enter
SETUP MENU Main menu R
MODE MENU R
RUN MODE Load cell unwind, X UW R
AMPLIFIER x1 or x10 preamplifier E
0/4 mA Output 0-20mA or 4-20 mA E
LANGUAGE English, German, French, Spanish, Danish AE
GAIN System gain 0-63 AE
RATIO System ratio 0-63 AE
P-LEVEL Proportional level 0-63 AE
D-LEVEL Derivative level 0-63 AE
SOFTS MENU Submenu for softstart. Enter menu to change parameters. R
ANTI MENU Submenu for anticoast. Enter menu to change parameters. R
SPLCE MENU Submenu for splice. Enter menu to change parameters. R
WEBBR MENU Submenu for web break. Enter menu to change parameters. R
RANGE EXP. Submenu for range expander. Enter menu to change parameters. R
DIAM. MENU Submenu for calculation of diameter. Enter menu to change parameters. R
OUTPUT2 MENU Submenu for extra analog output Output2. Enter menu to change parameters. R
62 1/3/02
3.19 Hardware Adjustment and LEDs
3.19 Hardware Adjustment and LEDs R1 Zero Range Adjusts analog tension meter (or digital display) to zero with no load on the load cell (zero
adjustment) (see tension calibration procedure in Section 4.1, p. 64).
R2 Calibration Range Adjusts analog tension meter (or digital display) to show actual web tension.
R3 Calibration Range Adjusts analog tension meter (or digital display) to show actual web tension on the high scale during use of a second calibration range.
R4 Diameter Zero Range Adjust until 0 is displayed in DIAMETER message (refer to diameter calibration in Section 3.12).
R5 Diameter Calibration Range Adjust until actual diameter is shown in the DIAMETER message (refer to diameter calibration in Section 3.12).
R6 Summation Input Calibration Not used in X-3000ce-UW.
R1 R2 R3 R4 R5 R6
Enter
-
+Back S pace
Down
Up
DI 6DI 5DI 4DI 3DI 2DI 1
DI 7DI 8
00
DO 4
DO 1DO 2DO 3
1
2
3
4 5
6
7
8
9 1
0 1
1 12
13
14
15 1
6 1
7 1
8 19
20
21
22 2
3 2
4 25
26
27 2
8 29
44
45
46 4
7 4
8 49
50
51 5
2 5
3 54
55
56 5
7 58
L N PE
TENSION 45 %
Type : X/D-3100Serial no : 960034Voltage : 115V/230V ACCurrent : <200 mA
220
110
30 3
1 3
2 3
3 34
35
36
37 3
8 3
9 40
41
42
43
11 1
2 13
14
R1 R2 R3 R4 R5 R6 R1 = Zero Calibration (Load cell Input)R2 = Range Calibration 1 (Load cell Input)R3 = Range Calibration 2 (Load cell Input)(See 4.1 Tension Calibration)
R4 = Zero Calibration (Diameter Input)R5 = Range Calibration (Diameter Input)(See 3.13 Diameter)
R6 = Summation Range Calibration(Not used in D- or X-3000ce-UW)
Potentiometers
DI 6DI 5DI 4DI 3DI 2DI 1
DI 7DI 8
DO 4
DO 1DO 2DO 3
DO4 = Range 3 (Range expander) Terminal 10DO3 = Range 2 (Range expander) Terminal 39DO2 = Range 1 (Range expander) Terminal 9DO1 = Range 4 (Range expander) or Web Break Terminal 38
Digital Output
DI8 = Anticoast Terminal 6DI7 = Roll Pulse Terminal 35DI6 = Web Pulse Terminal 5DI5 = Softstart Terminal 34 DI4 = Second cal. Terminal 3DI3 = Tension off Terminal 32DI2 = Splice Terminal 2DI1 = Manual Terminal 31
Digital Input
IL003.dsf
1/3/02 63
4 Calibration
4 Calibration
4.1 Tension Calibration
1. Check that load cells are mounted and oriented properly. Refer to the load cell installation instructions.
2. Before applying power, check that tension meter is mechanically zeroed. If not, adjust the small screw below the meter scale until the meter reads zero.
3. Apply power to the controller and let it warm up for at least 10 minutes.
4. With web removed and no tension applied to the sensing roller, adjust potentiometer R1 until analog tension meter reads zero. (If non-cabinet version is used, see digital display: tension should read 0%.) If value is below zero, turn R1 clockwise; if above, turn counterclockwise.
Note: R1 and R2 are 25-turn potentiometers, so many rotations may be required.
5. Thread a rope over the center of the tension-sensing roller following the exact path of the web. Make sure the rope extends at least one roller before and one roller after the sensing roller. Make sure the rope does not pass over any dead bars or non-freewheeling rollers. Fasten one end of the rope securely.
6. Attach a weight of known value to the other end of the rope. For best results, the weight should be at least 25% of the analog meter's full-scale value. A tension value below 0% with the weight hung indicates that the signal from the load cells is reversed. In the event of such a reversal, switch wires 12 & 14 and 41 & 43 on the terminal block. To eliminate friction, rotate rollers in the direction of the weight.
For cabinet and non-cabinet versions of the controller, see section 2.2, p. 9.
MANUAL
MANUAL/ AUTO
AUTO
TENSIONOFF / ON
T
20 80
50
20 80
50
20
OUTPUT
IL004.dsf
R1 R2 R3 R4 R5 R6
+Back SpaceUp
DO 4DO 3DO 2DO 1
00
Load cell
IL005.dsf
64 1/3/02
4.2 Regulation Parameter, Gain, Ratio, P and D
7. Adjust potentiometer R2 until analog meter reading is identical to the hanging weight. (If non-cabinet version is used, see digital display: tension will appear as a percentage value [%]).
8. Remove weight and check that tension meter returns to zero. If not, repeat steps 4 to 7.
9. If a second calibration range is used, repeat steps 4 to 8, using potentiometer R3 for calibration of second range.
4.2 Regulation Parameter, Gain, Ratio, P and D
Gain. At small roll diameters, adjusts speed of regulator's response to errors. The parameter can be adjusted in a range of 0 to 63 steps. The higher the value, the faster the reaction to errors. Not recommended: parameters lower than 5.
Note: To access setup menu, scroll to [Password] and enter 5.
Ratio. At large roll diameters, the ratio adjusts speed of regulator's response to errors. The parameter can be adjusted in the range of 0 to 63 steps. The higher the value, the faster the reaction to errors. Not recommended: parameters lower than 10.
P-level. Proportional gain level of the PID regulator. The parameter can be adjusted in a range of 0 to 63 steps. The higher the value, the bigger the P- level in the PID regulator.
D-level. Derivative gain level of the PID regulator. The parameter can be adjusted in a range of 0 to 63 steps. The higher the value, the bigger the D -level in the PID regulator.
Note: for load cell controllers, D-level is normally set at 0.
R1 R2 R3 R4 R5 R6
+Back SpaceUp
DO 4DO 3DO 2DO 1
00
Load cell KG
IL006.dsf
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
1/3/02 65
4 Calibration
4.3 Tuning
1. Calibrate load cells as described in Section 4.1.
2. If used, set up range expander before running.
3. If used, set up diameter at diameter menu before running.
4. Tune with machine running at low speed. Place a small roll in the unwind stand, and adjust [Gain] until tension has stabilized but is still responsive to errors.
5. Place a large roll in unwind stand and adjust [Ratio] until tension has stabilized but is still responsive to errors.
6. Scroll to [Softs Menu] and adjust the start out, soft start level and soft start time to fit machine acceleration and speed.
7. If anticoast is used, scroll to [Anti Menu] and adjust level to fit machine deceleration time.
8. If used, set up and adjust web break or splice.
DiagnosticPasswordSetup Menu
Mode MenuRun ModeAmplifier0/4mALanguage
GainRatioP LevelD LevelSofts Menu
Start OutSofts Lev.Softs TimeHold Level
Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope
Splce MenuSplice SrcSplice DelSplice LevSplice Tim
WebBr MenuWebbr Lev.Webbr Time
Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu
Range Dia MenuDia. Menu
Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter
Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off
66 1/3/02
4.4 Customer Parameter Settings
4.4 Customer Parameter Settings*Visible if and only if source = PULSE. **Visible if and only if source = LOCAL.
Parameter Factory Min. Max. UNITValue: Setting:
Mode Menu Mode X-UNWAmplifier X10 X1 X100 / 4 mA 4 mA 0 4
Language ENGLISGain 20 0 63Ratio 31 0 63P Level 30 0 63D Level 0 0 63Softs Menu Start Out 50 1 100 %
Softs Lev. 90 0 200 %Softs Time 5.0 0.1 99.9 SHold Level 100 0 200 %
Anti Menu Anti. Src. OUTPUTAnti max 50 0 500 %Anti min 2.0 0.0 20.0 %Anti Slope 2.7 0.0 3.0 %
Splce Menu Splice Src NONE Splice Del 0.2 0.0 1.0 SSplice Lev 50 0 200 %Splice Tim 1.0 0.5 5.0 S
WebBr Menu Webbr Lev. 5 -95 25 %Webbr Time 2.0 1.0 5.0 S
Range Exp. RE Source NONERanges 1 1 4Start No. 1 1 4Dn Level 20 0 100 %Up Level 80 0 100 %Range Time 20 1 60 SBrake Menu Pads R1 1 1 10
Pads R2 1 1 10Pads R3 1 1 10Pads R4 1 1 10Randomize YES
Range Dia Menu 4->3 Dia 83 0 100 %3->2 Dia 56 0 100 %2->1 Dia 28 0 100 %
Dia. Menu Diamet.Src LOCAL*P/Rev Roll 1 1 900 pulse*mm/Pulse 50 1 900 mmMin Diam. 10 0 500Max Diam. 100 0 2250**Fac. Diam 200 0 1000 %**DF AutosetNew Roll D 100 0 2250Diameter %
Output2 Menu Out2 Src DIAOut2 Slope 1.0 1.0 3.0Out2 Scale 100 0 200 %Out2 Off 0 0 100 %
Parameter Name:
1/3/02 67
5 Operation
5 OperationWeb Tension Meter
Displays actual web tension from 0 to 100%. Scale as required for application.
Output Meter
Displays regulated output from 0 to 100%. For best controller performance, output should be as high as possible at maximum roll size. With Montalvo brakes, activate or de-activate friction pads to adjust torque capacity.
Mode Switch - Auto/Manual
Used to select either AUTOMATIC (closed loop) or MANUAL (open loop) mode of operation.
Tension Switch
Used to turn regulator output off and on.
Low/High Scale Switch (optional)
Selects calibration range and meter scale in use.
Manual Potentiometer
Sets output of the controller when in MANUAL mode. No automatic regulation is done while in manual, so the operator must make constant adjustments to maintain the correct tension level. Also, there is no regulation of the range expander.
Auto Potentiometer (Setpoint)
Sets desired setpoint of controller when in AUTO mode. In automatic the actual web tension is compared to the desired tension (setpoint). The output is automatically adjusted to maintain set tension. Output changes proportionally with roll diameter and other factors that may affect web tension. The AUTO setpoint can be adjusted from 0 to 100% of the maximum displayed tension.
Auto/Manual Switching
When switching from MANUAL to AUTO, controller starts at the manual output, then regulates to the output required for automatic control. When switching from AUTO to MANUAL, controller immediately changes from AUTO to MANUAL set value. This may cause large tension changes. To avoid this, note the output while running in automatic. Set the MANUAL potentiometer to the approximate percentage of the auto output to maximum output. For example, if the auto output is 50% of the maximum, set the manual output potentiometer to 50%.
Soft Start
When controller receives a signal for machine to stop, after soft start delay time it switches into soft start mode. When machine is started, controller automatically switches into the auto mode. Soft start prevents the machine from starting with the output at maximum if the web has been slack during a stop.
68 1/3/02
5 Operation
Splice Level Potentiometer (Optional)
Sets the new roll starting output after splice.
Power Diode
The green LED indicates that the unit is on.
50
20 80
100%0
MANUAL AUTO
TENSION OFF/ON
AUTOM A N U A L
OUTPUT
50
20 80
100%0
Type: X3000-ce-UW SN: 3455Supply voltage: 115/230V 60/50HzSupply current: <0.5A
IL007.dsf
1/3/02 69
6 Troubleshooting
6 Troubleshooting
Note: Diagram shows all possible functions for this circuit board. Some, however, are either not used in this configuration, or are available only as options at an additional cost. Consult factory for further details.
UI
0/4-
20 m
A
Opt
iona
l 0-1
0V in
put
to 0
/4-2
0 m
A ou
tput
1.58
1.29
-++
x1/x
10
+-ZE
RO
R1
R2
CAL
. 1
R3
CAL
. 2+2
.5V
-2.5
V
ab c
abc
Load
cell
1Lo
adce
ll 2
1.14
,41
1.42
1.13
1.12
,43
Load
sen
sor
rolle
r
Tens
ion
outp
ut 0
-10V
Tens
ion
outp
ut 0
-100
uAEx
tern
al te
nsio
n in
put
Tension AI 2
Cal
. sel
ect
DO
+10V
+10V
1.20
1.19
1.18
1.23 1.22
1.21
Tape
r %
Auto
setp
oint
X++
Rem
ote
setp
oint
AO1
Setp
oint
inpu
t AI1 - +
0VD
C
+10V
+10V
1.49
1.48 1.47
1.52 1.51
1.50
Splic
e in
put
Man
ual
setp
oint
Man
ual i
nput
AI4
Splic
e in
put A
I5
Opt
iona
l ana
log
outp
ut0-
10V
1.57
Anal
og o
utpu
t AO
4
+10V
1.27 1.25
1.24
Dia
met
er in
put
++
x1/x
10
+-ZE
RO
R4
R5
CAL
.
1.23
Dia
met
er in
put A
I6
Dia
met
er c
alib
rate
d
XI P D
Gai
n
Rat
io
P D
Sum
mat
ion
inpu
t1.
53
1.54
R6
SUM
MAT
ION
SUM
MAT
ION
IN
PUT
AI7
DIS
PLAY
16
CHA
R.
EPRO
M
RAM
DIG
IPO
TEE
PRO
M
RS48
5DI
GIT
AL
CONT
ROLL
ER
I/O INTERFACE
+24V
DC
DI1
1.4,
33,3
6
1.31
DI2
1.2
DI3
1.32
DI4
1.3
DI5
1.34
DI6
1.5
DI7
1.35
DI8
1.6
1.1,
30
Supp
ly D
O1.
7
DO
11.
38
DO
21.
9
DO
31.
39
DO
41.
10
1.8,
37
1.57 1.16
1.17
Anal
og o
utpu
t
Cur
rent
out
put
Reg
ulat
ed o
utpu
t
Tota
l out
put A
I8
1.56 1.15
IntegraterAI3
Exte
rnal
gai
n1.
55
+10
V
Pow
er s
uppl
yIn
put :
115/
230
V A
CO
utpu
t :+5
VDC
+/- 2
.5 V
DC
+/- 1
5 VD
C+2
4 VD
C
10.L
10.N
10.P
E
UI
X-30
00ce
Blo
ck D
iagr
am
0VD
C
0VD
C
0VD
C
0VD
C
0VD
C
0VD
C
0VD
C
0VD
C
0VD
C
1.45
1.46
WD011.dsf
70 1/3/02
6 Troubleshooting
If use of the X-3000ce-UW controller is no longer required, dispose of it according to regulations in force at the time.
For service, please contact:
Symptom Cause Check for
Web tension unstable both in AUTO and MANUAL modes...
Mechanical problemBad roll, bad bearings, bent shafts, worn gears, missing teeth, loose chains or belts, line speed variations, brake, clutch or drive problem.
Pneumatic problem Fluctuating air input, air leaks, water or oil in air lines.
Web tension and output stable in MANUAL, but unstable in AUTO...
Tuning problem Check regulator tuning. See Section 4.3, "Tuning‚" p. 66.
Regulator problem Check terminal points - if faulty, consult factory or replace circuit board.
Converter problem If signal voltage OK, replace converter.
Web stable in manual, but tension meter reading unstable...
Load cell problem Loose load cell mounting, cables, plugs, or unbalanced roll.
Tension meter Defective meter, loose connections.
Regulator problem Check + 2.5 V supply, tension output at 1.45.
Tension meter fails to read zero when web is slack...
Load cell problem Faulty or improperly installed load cells.
Adjustment problem See Section 4.1, "Tension Calibration‚" p. 64.
Web tension too low both in AUTO and MANUAL modes...
Pneumatic problem Check input air pressure and for air leaks. I/P converter may be defective.
Regulator problem Check terminal points - if faulty, consult factory or replace circuit board.
Brake/drive problem Brake/clutch too small, not enough pads activated, motor too small, drive current limit set too low.
Unwind - Tension increases at small roll diameters both in AUTO and MANUAL modes...
Mechanical problem Bearings in unwind defective, too much friction.
Pneumatic problem I/P converter may be defective.
Regulator problem Check terminal points, replace regulator if defective.
Brake problem Brake too large, too many pads activated.
The Montalvo Corporation50 Hutcherson DriveGorham, ME 04038 USATel. (207) 856-2501Fax. (207) 856-2509
Email: [email protected] site: www.montalvo.com
Danarota Technic A/SGI. Skartved 5 DK-6091 Bjert, DenmarkTel. +45 75 57 27 11Fax +45 75 57 29 97
1/3/02 71
The Montalvo Corporation • 50 Hutcherson Drive, Gorham, Maine 04038 USA • Email: [email protected] • www.montalvo.comTel: (207) 856-2501 • Fax: (207)856-2509 • Toll Free Tel: 1-800-226-8710 • Toll Free Fax: 1-800-644-5097
Technical details subject to change without notice. Printed in U.S.A. X-3000ce-UW © 2001 MONTALVO