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DFE SteadyWeb, Instruction Manual

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INSTRUCTION MANUAL

S

TEADY

W

EB

™

AUTOMATIC TENSION CONTROLLER 

DOC 801-0783

Summary of Contents for SteadyWeb

Page 1: ...INSTRUCTION MANUAL STEADYWEB AUTOMATIC TENSION CONTROLLER DOC 801 0783...

Page 2: ...products and special systems Please call 603 332 6150 and ask for Sales or email to us at sales dfe com Telephone 603 332 6150 Fax 603 332 3758 E mail info dfe com Internet www dfe com 1999 Dover Fle...

Page 3: ...d start it up it should only be necessary to use these sections of this manual Section 2 Installation Section 4 Calibration the Tension Meter Section 7 Tuning for Running Stability The other sections...

Page 4: ...ion Selection normal reverse 4 Output Meter 4 Power Voltage Selection 4 Ratio 5 Remote Tension On Off 5 Remote Tension Set 5 Sample Hold 5 Soft Start 5 Speed Follow 5 Speed Match 5 Status Lights 5 Ten...

Page 5: ...5 6 Emergency Stop 25 5 7 High Voltage Output Module 12V only 26 5 8 Meter Correlation 27 5 9 Meter Damping 27 5 10 Output Direction 27 5 11 Output Meter 28 5 12 Pneumatic Output Module 12P only 28 5...

Page 6: ...NT PARTS 8 0 Standard Circuit Boards 52 8 1 Optional Circuit Boards 52 8 2 Operator Devices 52 8 3 Output Modules 52 8 4 Fuses 52 8 5 Ribbon Cables 52 8 6 Relays 53 8 7 Miscellaneous 53 APPENDICES A L...

Page 7: ...nsion On Off Button Connections 30 23 Sample Hold Contact 31 24 Soft Start Connections 32 25 Transducer Voltage Switch 35 26 DC Tach Option Card 36 27 DC Tachometer Connections 37 28 Digital Meter Dis...

Page 8: ......

Page 9: ...available for the SteadyWeb controller A Pneumatic output module This is used to actuate any air operated brake or clutch It includes a servo valve a pressure regulator and an air filter These items a...

Page 10: ...2 1 2 STEADYWEB CONTROLLER EXPLODED VIEW Figure 1 STEADYWEB CONTROLLER EXPLODED VIEW...

Page 11: ...rated load 1 0 Volt with Extended Range option MATING TRANSDUCER CABLE CONNECTORS Amphenol MS3106A 10SL 3S ZERO TARE RANGE 95 of transducer rating minimum CALIBRATION RANGE 25 1 TEMPERATURE RANGE 32...

Page 12: ...ned only by the position of the MANUAL set knob No change occurs unless the knob is turned Used during machine set up or during trouble shooting METER CORRELATION ADJUSTMENT This causes the position o...

Page 13: ...Card see Options Section 1 5 SPEED FOLLOW This is a special function normally used on Version 12D SteadyWebs controlling tension in an intermediate zone see Tension Zone drawing Section 5 0 page 20 o...

Page 14: ...ng stability setups The meter scales may have any ratio limited only by the range of the transducers Used in those cases in which a wide range of materials having very wide tension requirements are be...

Page 15: ...p TAPER ADJUSTMENT ON FRONT PANEL XTA Instead of inside controller TAPER TENSION For rewind applications Causes tension to decrease as roll diameter increases Helps produce a better quality roll by el...

Page 16: ...8 1 6 FRONT PANEL AND OPERATOR DEVICES Figure 2 FRONT PANEL and OPERATOR DEVICES...

Page 17: ...11 78 9 41 10 54 4 71 42 mm 316 265 197 36 61 6 299 239 268 120 11 Note Allow 5 127mm clearance on the left side for the controller to open completely FRONT SIDE BACK REMOTE PNEUMATIC ASSEMBLY DIMENSI...

Page 18: ...e controller won t be struck and damaged by anything or anyone The enclosure is fastened to the mounting surface you have chosen by two socket head cap screws Install the screws in the mounting surfac...

Page 19: ...ectrical connections If your controller has any optional equipment refer to Section 2 3 or Appendix D of this manual for the appropriate connections TB201 TB203 and TB204 are located on the Power Boar...

Page 20: ...12 2 3 ELECTRICAL CONNECTIONS OF OPTIONS Figure 7 ELECTRICAL CONNECTIONS OF OPTIONS...

Page 21: ...ENCLOSURE CONFIGURATION The H6 Harness 6 ft long configuration consists of the standard enclosure with the cover omitted and the front panel removed and connected to the controller by a harness or ri...

Page 22: ...3 S T U V W X Y Z AA inch 8 09 163 Dia Typ 2 19 Dia Typ 2 40 65 1 24 28 1 58 7 35 mm 205 4 1 4 8 10 17 31 7 40 184 Figure 9 DIMENSIONS OF H6 ELECTRICAL CONNECTIONS OF H6 CONFIGURATION All electrical c...

Page 23: ...on the controller An interface card is mounted on the cover plate The card contains a terminal strip for connection to the external operator devices All other electrical connections are made in the u...

Page 24: ...CONFIGURATION INTERFACE BOARD CONNECTIONS Electrical devices are connected to both the Interface Board and the Power Board See next page for Power Board connections Figure 12A ELECTRICAL CONNECTIONS...

Page 25: ...17 ELECTRICAL CONNECTIONS OF CC CONFIGURATION POWER BOARD CONNECTIONS See previous page for connections to the Interface Board Figure 12B ELECTRICAL CONNECTIONS OF CC CONFIG on POWER BOARD...

Page 26: ...LES 4 1 CALIBRATE THE METER FOR ACCURACY Refer to Figure 16 or 41 for adjustment pots a Find an object of known weight at least as heavy as 25 of the tension meter full scale number A fish scale can a...

Page 27: ...quired to set the meter needle at the value of the weight g Remove the weight and observe the tension meter If the needle is not on 0 adjust the ZERO A pot as needed Repeat step f h Repeat steps f and...

Page 28: ...ones are created by driven or braked nip rolls drag bars braked or driven unwind or rewind shafts or anything else that can increase or decrease web tension One of these elements is at each end of eve...

Page 29: ...21 5 1 THE CONTROL BOARD Figure 16 CONTROL BOARD...

Page 30: ...22 5 2 THE POWER BOARD Figure 17 POWER BOARD...

Page 31: ...ule when used It is also drives the isolated 10 volt output module on Version 12D controllers Set the LIMIT and LIMIT adjustments and the SW103 DIP switches as follows a Refer to the information below...

Page 32: ...output b Verify that the 0 10 volt tension output produces 10 volts DC when the tension meter reads full scale 100 Measure at terminal strip TB203 terminals 42 and 44 If not calibrate the meter See Se...

Page 33: ...e required Works in the MANUAL control mode too a Choose between zero output and full output upon actuation The status light on the front panel will light when Emergency Stop is activated b Connect th...

Page 34: ...tches as follows SW401 SWITCHES 0 90VDC Out 115VAC In 0 45VDC Out 115VAC In 0 24VDC Out 115VAC In 0 90VDC Out 230VAC In 0 45VDC Out 230VAC In 1 Open 1 Open 1 Closed 1 Open 1 Closed 2 Closed 2 Closed 2...

Page 35: ...ting If the correlation between the tension meter and the AUTO pot is satisfactory quit here If not proceed to Step b b Run the machine at normal speed with any normal tension showing on the meter Be...

Page 36: ...output meter reads 0 d Set the M SENS pot RT202 so the output meter reads 100 at full output Turn the TEN TRIM pot on the Control board fully clockwise to enable full output Adjust the M SENS pot so...

Page 37: ...2 turn CW Turn the RATIO DLY pot 1 2 turn CW c Connect the external contact as shown below Figure 21 RATIO CONTACT ELECTRICAL CONNECTIONS d FOR UNWINDS Run the machine slowly with the controller in t...

Page 38: ...en 2 Closed 3 NA 3 NA 4 NA 4 NA NA Not Applicable 5 15 REMOTE TENSION ON OFF See Page 5 for description This requires two momentary contact N O pushbuttons Connect them as shown below Figure 22 REMOTE...

Page 39: ...panel will light when Soft Start is activated 1 Actuation by low tension This is the standard configuration a Turn off soft start when the controller is being used to control rewind or intermediate te...

Page 40: ...ion e Set the SS LINE TRIP pot fully CCW to avoid interference with the SS TEN TRIP pot 2 Actuation by external contact closure a Connect the external switch or relay contact as shown The controller w...

Page 41: ...The range is about 0 to 100 of maximum line speed Turn the pot CW to increase the actuation speed Set the pot to about 5 Do NOT leave it at 0 or Soft Start will be active all the time d Set the SS LIN...

Page 42: ...NA 6 NA 6 NA 6 NA 7 NA 7 NA 7 NA 8 NA 8 NA 8 NA 5 21 TLS CARD INSTALLED See Page 7 for description Figure 16 for switches The SW104 switches must be set according to the presence or absence of the op...

Page 43: ...35 Set the SW202 switch as follows 5VDC Slide switch UP 10VDC Slide switch DOWN Figure 25 TRANSDUCER VOLTAGE SWITCH...

Page 44: ...e 6 2 45 VOLT OUTPUT Version 12V controller only see Page 6 for description Refer to Section 5 7 for correct set up procedure 6 3 DC TACHOMETER CARD See Page 6 for description This card is only used i...

Page 45: ...H voltage NOTE If desired run the machine at 50 of maximum speed In this case the LTACH output voltage will be set at 5 0 volts instead of 10 volts and the RTACH output voltage will be set at 50 of th...

Page 46: ...r 10 0 volts AT THE CORE DIAMETER As an alternate method measure the roll diameter and adjust the RTACH Span pot to a voltage equal to 10 x core diameter roll diameter h Note If you ran the machine at...

Page 47: ...cale tension is very high it is best to use the maximum of decimal places This produces a stable display c Turn off power Remove the mounting screws for the Control board to expose the back side of th...

Page 48: ...has no adjustments or switches to set The Dual Calibration option is required Follow the setup procedure in Sections 4 and 6 5 for each position of the transducer set selector switch This switch is lo...

Page 49: ...he machine INITIAL SW601 SETTINGS 1 Closed 2 Open 3 Open 4 Closed c Determine the maximum pulse amplitude of pulses from the LTACH and the RTACH pulse tachs The data sheet that came with them should g...

Page 50: ...the LTACH output voltage at test points TP601 and TP603 Adjust the LTACH Span pot RT601 for 10 0 volts i Set the RTACH span pot With the machine running at full speed measure the RTACH output voltage...

Page 51: ...EMOTE TENSION AMPLIFIER ELECTRICAL CONNECTIONS 6 10 TAPER ADJUSTMENT ON FRONT PANEL See Page 7 for description No special calibration procedures are needed This option is selectable by SW501 or SW801...

Page 52: ...r 0 volts DC at the same speed as core f Repeat steps d and e as needed to ensure that tension begins to decrease at slightly above core diameter and continues to decrease until full roll diameter is...

Page 53: ...ER ROLL CONNECTIONS Figure 36 10 VOLT SOURCE CONNECTIONS b Set the SW801 switches to select between the local taper adjustment pot and an optional pot located on the controller front panel SW801 SWITC...

Page 54: ...o the amount of tension decrease desired When the pot is at 0 tension remains constant from core to full roll When it is at 100 tension decreases linearly from the set level at core to 0 at full roll...

Page 55: ...l and turn the pot until the meter reads the desired trip point e Set the HIGH trip point Move the SELECT switch SW402 to the HIGH position rightmost position if switch is rotary If no High trip point...

Page 56: ...48 Figure 39 TLS RELAY CONNECTIONS...

Page 57: ...ler may be unstable The STABILITY pots coarse and fine adjustments are provided provide variable amounts of damping If set too low the controller may be unstable If set too high the controller may ign...

Page 58: ...ller make it at or near full roll diameter These are the points where the setting is most critical e Accelerate and decelerate the machine while watching the tension meter If tension oscillates readju...

Page 59: ...asure the surface speed of a driven roll running at machine speed Then measure the surface speed of the driven nip roll that is controlled by the SteadyWeb Adjust the LTACH Span pot on the TACH card t...

Page 60: ...ushbutton cap white 111 0004 Tension meter analog 721 0156 specify scale Tension meter digital 723 0289 optional 8 3 OUTPUT MODULES Vout board 723 0034 High voltage output module for version 12V Pneum...

Page 61: ...tion on Power board Vout card 105 0001 For version 12V only Dual Trans Input card 105 0020 option 8 7 MISCELLANEOUS Air filter 119 0002 For version 12P only Air pressure regulator 119 0004 For version...

Page 62: ...54 Appendix A Location of Standard Adjustments CONTROL BOARD Figure 41 STANDARD ADJUSTMENTS CONTROL BOARD POWER BOARD Figure 42 STANDARD ADJUSTMENTS POWER BOARD...

Page 63: ...cal tension signal C O Use Remote tension signal O C Use Local Auto Set pot C O Use Remote Auto Set pot O C SW103 page 23 Control Voltage 1 2 3 4 0 to 10 C O 0 to 10 O C 10 to 10 O O SW104 pages 31 32...

Page 64: ...O O 0 90 O C O C 0 45 C O O C 0 24 O C O O This is a factory installed option only TAPER DIA CALC CARD option Fig 33 SW501 page 44 1 2 3 4 Use Taper Pot on Card O C Use Taper Pot on Front Pnl C O PUL...

Page 65: ...s C O Note 53 54 55 56 are terminals on TB204 on Power Board SW702 and SW703 pages 37 38 Tach Voltage 1 2 3 4 Initial Settings O O O C 3 to 4 C O O O 4 to 16 O C O O 16 to 64 O O C O 64 to 250 O O O C...

Page 66: ...ches on the Power board Appendix B Sections 5 and 6 6 Set the transducer voltage selection switch on the Power board Section 5 22 7 Turn On the AC power to the controller and check the power supplies...

Page 67: ...18 first Section 5 18 16 Check operation of Sample Hold Section 5 17 17 Adjust the Ratio function if used Section 5 13 18 Adjust the DC TACH or PULSE TACH card if used Section 6 3 DC Tach card Sectio...

Page 68: ...x D Electrical Connections of Standard SteadyWeb TB203 and TB204 are located on the Power Board Figure 17 See Section 3 1 for electrical connections of CC configuration Figure 43 STANDARD ELECTRICAL C...

Page 69: ...rical Connections of Options for Standard SteadyWeb Unit TB203 and TB204 are located on the Power Board Figure 17 See Section 3 1 for electrical connections of CC configuration Figure 44 OPTIONAL ELEC...

Page 70: ...62 Appendix F Transducer Electrical Connections Figure 45 MODELS C RS UPB TRANSDUCER WIRING...

Page 71: ...63 Figure 46 MODEL RFA VNW TRANSDUCER WIRING...

Page 72: ...64 Figure 47 MODELS TR NWI TRANSDUCER WIRING...

Page 73: ...65 Figure 48 MODEL LT TRANSDUCER WIRING...

Page 74: ...lb POLYETHYLENE 0 12 lb per mil per inch of width POLYESTER Mylar 0 75 lb per mil per inch of width POLYPROPYLENE 0 25 lb per mil per inch of width POLYSTYRENE 1 0 lb per mil per inch of width RUBBER...

Page 75: ...67 Appendix H Front Board There are no adjustments or switches on this board It is shown here for illustration purposes only Figure 49 FRONT BOARD...

Page 76: ...Improper calibration may cause unstable operation 5 Verify the setting of the meter correlation pot The setting is not critical however if it is grossly misadjusted the tension set pot on the front p...

Page 77: ...he financial condition or payment practices of the Buyer does not justify shipment under the standard terms or the terms originally specified the Company may require full or partial payment in ad vanc...

Page 78: ...CC 15 17 Manual Control Mode 4 Meter correlation Pot 4 27 damping 4 27 mechanical Zero 18 non standard meter scale 6 Metric Air Tubing 6 Mounting Screws 10 15 Operator Devices 8 replacement 52 Option...

Page 79: ...Switch 7 46 Tension Meter 3 5 8 18 27 52 standard scales 3 digital 6 38 40 52 Tension Output 0 10V 4 11 4 20mA 4 11 Tension Output 0 20m 24 Tension Zones 20 Terms Conditions 69 Transducer Voltage Sele...

Page 80: ...U S A TEL 603 332 6150 FAX 603 332 3758 E mail info dfe com Internet www dfe com CANADA MEXICO UNITED KINGDOM EUROPE TAIWAN KOREA AUSTRALIA COLOMBIA INDIA SOUTH AFRICA CHINA 1997 DOVER FLEXO ELECTRONI...

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