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INSTRUCTION MANUAL

WEBHANDLER 3

™

Tension Controller

Digital

DOC 801-1667

5 YEAR WARRANTY

DOVER FLEXO ELECTRONICS, INC.

ISO 9001 CERTIFIED

Summary of Contents for WebHandler 3

Page 1: ...INSTRUCTION MANUAL WEBHANDLER 3 Tension Controller Digital DOC 801 1667 5 YEAR WARRANTY DOVER FLEXO ELECTRONICS INC ISO 9001 CERTIFIED...

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 2006 Dover Fle...

Page 3: ...at our factory To install it and start it up it should only be necessary to use these sections of this manual Section 2 Installation Section 3 Calibration and Set Up The other sections are for referen...

Page 4: ......

Page 5: ...2 Tension Calibration 14 3 3 Line Speed Calibration and Set up 15 3 4 Roll Diameter Calibration and Set up 20 SECTION FOUR SET UP OF STANDARD OPTIONAL FEATURES 4 1 Basic Set up of Controller 23 4 2 Se...

Page 6: ...n and Miscellaneous Features Screens 28 30 PCWebLink Diagnostic Screens 29 31 PCWebLink Tuning and Data Transfer Screens 29 32 Sort Start by External Contact Connections 32 33 Sample Hold Connections...

Page 7: ...e second part is the tension regulator It compares the output signal from the transducers with the Auto set point value If there is a difference the regulator will either increase or decrease its outp...

Page 8: ...y air operated brake or clutch The standard version includes a servo valve air filter and pressure regulator installed in an separate enclosure The output range is 0 5 to 75 psi 0 03 bar to 5 17 bar A...

Page 9: ...3 1 3 WebHandler3 EXPLODED VIEW Figure 3 WebHandler Model 3 EXPLODED VIEW...

Page 10: ...per pair at rated load 1000 mV with XR option Mating Transducer Cable Connectors Amphenol MS3106A 10SL 3S Zero Tare Range 95 of transducer rating minimum Calibration Range 25 1 max Temperature Range...

Page 11: ...erial interface can also be used to accept commands from a host computer SERVO VALVE ASSEMBLY Standard for Version P Allows servo valve to be installed close to the brake clutch while the controller i...

Page 12: ...e of special indicator functions such as intrinsic safety which are not available in the WebHandler Model 3 controller REMOTE TENSION SWITCH RTS Tension On Off switch installed in remote enclosure wit...

Page 13: ...7 SECTION 2 INSTALLATION 2 1 DIMENSIONS inches mm Figure 4 CONTROLLER ENCLOSURE Figure 5 PNEUMATICS ENCLOSURE FOR VERSION P...

Page 14: ...enclosure is fastened to the mounting surface you have chosen by two socket head cap screws Install the screws on the mounting surface to match the screw hole dimensions on the back surface of the Web...

Page 15: ...n voltage switch is located at the upper left corner of the power board Confirm that the correct transducer excitation has been selected 5 Volts is standard 10 Volts provides a wider operating range T...

Page 16: ...2 5 1 ELECTRICAL CONNECTIONS FOR POWER BOARD STANDARD AND OPTIONS See Figures 3 and 6 for locations of Power Board terminal strips Figure 10 ELECTRICAL CONNECTIONS FOR POWER BOARD STANDARD AND OPTION...

Page 17: ...URES Depending on the feature you will be using you may not need to make all of the connections shown These connections are made on the Terminal Board See Figure 3 for location of Terminal Board Figur...

Page 18: ...3 ELECTRICAL CONNECTIONS FOR OPTIONS AND ACCESSORIES These connections are made on the Terminal Board See Figure 3 for location of Terminal Board Figure 12 ELECTRICAL CONNECTIONS FOR OPTIONS AND ACCES...

Page 19: ...de the top line of the display shows the measured tension and if Output is enabled ON will appear to the right If output is not enabled Tension is Off OFF will appear to the right instead The controll...

Page 20: ...pressing the or keys then OK Once you are in a function you can use the or keys to adjust a value or make a selection When complete you can press the OK key to save a value or the EXIT key to exit th...

Page 21: ...SPEED CALIBRATION AND SETUP Line Speed Calibration is required when you want to use the WebHandler in any of the following modes Line Speed Follower Diameter Compensated Line Speed Follower Taper by D...

Page 22: ...used you may verify that your DC Roll Tachometer is connected to TB102 pins 6 signal and 4 signal See Figure 17 below Figure 17 DC TACHOMETER ELECTRICAL CONNECTIONS There are two 10 Vdc outputs on the...

Page 23: ...switches to accommodate the tach polarity measured at TB102 terminals 3 and 1 Use the following charts to set the switches based on which terminal is positive polarity SW701 SWITCHES NA Not Applicabl...

Page 24: ...If diameter Compensated Line Speed Follower or Taper Diameter Calculation is to be used you may verify that your DC Roll Tachometer is connected to TB102 pins 6 signal and 4 signal See Figure 12 There...

Page 25: ...ope Set the SW601 switches according to the maximum amplitude using the chart below SW601 SWITCHES LTACH Pulse Amplitude volts 3 4 25 2 0 Closed Open 1 0 50 0 Open Closed 3 Determine the frequency of...

Page 26: ...coming from inductive proximity sensors or encoders a Pulse tachometer card needs to be used If the two signals are 0 10V level such as from certain motor drives then no tachometer card needs to be u...

Page 27: ...the roll diameter and adjust the RTACH Span pot to produce a test point voltage of 10 x core diameter actual diameter Note If you ran your machine at half speed set the test point voltage to half of w...

Page 28: ...t the procedure Follow the prompts on the screen You will end up back at the Calibrate Rider function in the menu Press EXIT twice to return to the default display Proceed to section 3 4 D D CONFIGURE...

Page 29: ...ction you can choose to activate standard features for use in your application 1 Normally your controller will power up with Tension turned Off If you want to change this so that it powers up with Ten...

Page 30: ...for WebHandlers is RS 232 which will allow direct connection to laptop computers For industrial shop floor applications with longer cable runs higher noise immunity requirements and potential multidro...

Page 31: ...ting computer Again you will need to wire appropriately for either 2 wire or 4 wire as shown in the following figure Figure 25 RS485 CABLE CONNECTIONS For two wire RS485 connections use only pins 1 4...

Page 32: ...en press CLOSE b Go to Start Run browse to your chosen folder and highlight WH3Link_ exe Right click choose Create Shortcut and the shortcut will appear in DFE Drag the shortcut onto your desktop Clos...

Page 33: ...On or Off Controller mode Manual or Auto and Taper on or Off You can select Tension Display units and enter Auto and Manual Setpoints Taper Percent and Web Width Note that if you enter an erroneous v...

Page 34: ...ts Ratio multiplier and delay Power on control and tension modes Serial Communication Source see below Enable external tension switch Serial Network ID Remote auto manual switch and manual and auto se...

Page 35: ...e DEFAULT SETUP configuration see also 5 below To store a setup in your WebHandler Select DEFAULT SETUP in the Store Setup As pulldown box Click the STORE button You will be advised when Storing is co...

Page 36: ...ns to quickly configure multiple controllers for similar applications and for other uses To download a setup from a WebHandler to your computer As noted elsewhere your controller s current setup is st...

Page 37: ...ollers The choices of addresses are as described above Whenever the controller receives a command which requires a specific response to that command it responds with a prefix specific to that command...

Page 38: ...tension meter scale Avoid setting the trip point close to your operating tension Set it much lower instead Be sure the SS Output Level value is set high enough to produce enough tension to exceed the...

Page 39: ...ix A Figure 33 SAMPLE AND HOLD CONTACT CONNECTIONS Usually you will want to put the controller in Ratio the moment before the splice until the web has settled down from the disturbance of splicing The...

Page 40: ...In Latched mode a TLS alarm is triggered when the tension is below for TLS Lo or above for TLS Hi the corresponding setpoint If the tension goes back within the normal range the TLS alarm is not clea...

Page 41: ...nts This provides a simple reliable indication that tension is within range without external logic and can be used to sequence another part of the machine 7 FuncTimeoutTime As you set your controller...

Page 42: ...pin 3 or SoftStart Input pin 5 4 2 SETUP OF OPTIONAL FEATURES A REMOTE TENSION AMPLIFIER RTA Option See Figure 9 Terminal Board for location of TB101 This feature allows a 0 10V tension signal from an...

Page 43: ...ler3 has a number of preprogrammed full scale tension ranges to choose from However if your application requires a range not included as standard it is possible to enter a different full scale range a...

Page 44: ...PAN pot RT1 slowly clockwise until the desired voltage is obtained 7 If the output voltage is higher than the chosen range slowly turn the SPAN pot RT2 count clockwise until the desired output is obta...

Page 45: ...ch making sure tubing does not contact any moving parts on the machine 2 Select desired output 0 to 10V or 4 to 20mA by positioning the jumper on JP1of the driver card The jumper should cover pins 1 a...

Page 46: ...n a tension error and a high setting will produce a large output change If set too high the controller may be unstable A typical setting would be 5 15 2 The STABILITY setting provides variable amounts...

Page 47: ...y first If Stability will not hold steady tension use Gain 5 Then vary the Gain and or Response setting to minimize the time needed for tension to return to the set value Very low response values are...

Page 48: ...ottom line will change to MAN SETPT and the output will be generated according to the manual set point This Mode has no PID function think of this as a speed Pot control for your output To change this...

Page 49: ...open the cover and on the Control Board located on the door locate RT3 Using a small screwdriver turn it in either direction to obtain optimum contrast Note that this only adjusts contrast not bright...

Page 50: ...nt to recall When you have chosen one press OK again The display will pause then show an asterisk in the rightmost space then the second line will blank out Press Exit to return to the menu See also S...

Page 51: ...re zero the tension reading Follow the on screen prompts Your Calibration will still be Valid This function is used to compensate for minor transducer variations from thermal change or buildup of mat...

Page 52: ...a period of time If so you may consider moving the unit or putting the unit in an enclosure more suited to your particular environment Washing the exterior of the unit may be done using warm water an...

Page 53: ...ibration of the tension meter is very important to the operation of the controller Be sure the calibration is correct Refer to Section 3 Improper calibration may cause unstable operation 5 If your con...

Page 54: ...tput module for version V Servo valve 119 0003 For version P only 8 4 FUSES Slo Blo type Power in 0 25A 250V 108 0046 All versions of controller 115 Vac 5A 250V 108 0003 For version V only on V Out Bo...

Page 55: ...49 Appendix A Circuit Boards Figure 45 CONTROL BOARD Figure 46 POWER BOARD top view...

Page 56: ...50 Figure 47 TERMINAL BOARD Figure 48 V OUT BOARD top view...

Page 57: ...51 Figure 49 NON STANDARD SERVO VALVE DRIVER CARD Figure 50 ISOLATED OUTPUT CARD...

Page 58: ...52 Figure 51 DC TACH OPTION CARD Figure 52 PULSE TACH OPTION CARD...

Page 59: ...litude volts 1 2 3 4 0 25 2 0 O C C O 1 0 50 0 C O O C SW602 SWITCHES RTACH LTACH Frequency 1 2 3 4 180 Hz 1 7 KHz C C C C 1 1 KHz 40 KHz O C C O V OUT BOARD SW401 POWER IN OUTPUT 1 2 3 4 115Vac 0 90...

Page 60: ...controller and check the power supplies Refer to Figures 6 or 44 the Power Board Verify the following voltages using the test points listed 15 Volt TP201 and TP204 15 Volt TP205 and TP204 5 Volt 10 V...

Page 61: ...55 Appendix D Function Menus Chart...

Page 62: ...rder to work properly Range of values 0 100 Default choice or value 50 Set Roll Dia Allows the user to enter the current roll diameter This is helpful when the controller is being used in Line Speed F...

Page 63: ...hoices 1 5 10 25 50 75 100 150 200 250 300 500 1000 1500 2000 2500 3000 Non Standard Default choice or value 100 Set CalibrationWt This function allows the user to enter the weight with which the tens...

Page 64: ...when the corresponding inputs change In very unique circumstances it is desirable to allow the tension in the controlled zone to stabilize before changing the roll diameter because doing otherwise wo...

Page 65: ...g OK key The Raw modes enable the alarm even if the measured tension was never in range first The alarm condition produces a message on the display as well as activating the TLS relay List of choices...

Page 66: ...ue Auto Mode ExtTens On Off When activated this function will allow an external input to turn tension mode On or Off Off prevents the external input from having an effect while On will allow the exter...

Page 67: ...point entry A potentiometer or 0 10V signal is then applied to that pin List of choices Front Panel Line Spd Input Roll Spd Input RTA Input Diameter Input Default choice or value Front Panel Aut Setpo...

Page 68: ...temporarily output other values for troubleshooting purposes Do not use this function unless instructed to do so by DFE Technical Support List of choices Tension Line Speed Roll Speed Direct Diam Remo...

Page 69: ...menu should be used only after you have already set your Zero value using the Zero Select ADC menu Note Before using this menu go to the Read ADC menu and cause some change to the input to verify tha...

Page 70: ...iameter value is contained in the following five bytes where the data format is XXX X e g _25 4 represents 25 4 inches centimeters or other units of distance measurement F Turn Tension Off Host instru...

Page 71: ...e stored setup Activate one of the stored setups 1 through 9 and make it the default e g 1P4 will take the setup in memory location 4 and make it the default Note due to the time required for the stor...

Page 72: ...g V_ _9 represents a manual set point value of 9 W Read Auto Setpoint Host inquires the current Auto Set point from the controller WebHandler response W 6 Set point value is contained in the following...

Page 73: ...67 Appendix G PCWebLink Screens Figure 53 PCWebLink RUN SCREEN Figure 54 PCWebLink CONFIG 1 AND CONFIG2 SCREENS...

Page 74: ...68 Figure 55 PCWebLink TLS AND SOFT START SCREENS Figure 56 PCWebLink CALIBRATION AND MISCELLANEOUS SCREENS...

Page 75: ...69 Figure 57 PCWebLink DIAGNOSTIC SCREENS Figure 58 PCWebLink TUNING AND DATA TRANSFER SCREENS...

Page 76: ...70 Appendix H Transducer Electrical Connections Figure 59 MODELS C RS UPB TRANSDUCER WIRING...

Page 77: ...71 Figure 60 MODEL RFA VNW TRANSDUCER WIRING...

Page 78: ...72 Figure 61 MODELS TR NWI TRANSDUCER WIRING...

Page 79: ...73 Figure 62 MODEL LT TRANSDUCER WIRING...

Page 80: ...b 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 G...

Page 81: ...ars If the Company judges that the 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 fu...

Page 82: ...76 NOTES...

Page 83: ...3 Output 0 75 psi 2 4 0 90 volt 2 4 0 24 volt 2 4 6 0 45 volt 2 4 6 PCWebLink Software Set up 26 31 Screens 26 29 66 68 Pneumatic enclosure 3 4 7 non standard DRVR option 38 output 4 input required 4...

Page 84: ...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 2006 DOVER FLEXO ELECTRONICS INC DOC...

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