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Montavlo X-3000ce-UW, Installation And Operating Instructions Manual

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Montavlo X-3000ce-UW Installation And Operating Instructions Manual Download Page 3

 1/3/02                                                                                                                                                                                                                        3

Table of Contents

1  General Description  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

2  Technical Data  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

2.1  X-3000ce-UW Electrical   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  8

2.2  X-3000ce-UW Mechanical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  9

3  lnstallation and Setup   - - - - - - - - - - - - - - - - - - - - - - - - - - -  11

3.1  Mechanical Installation  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  11

3.2  Electrical Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  14

3.3  Quick Setup Guide

   - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

3.4  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

  - - - - - - - - - - - - - - - - - - - - - - - - - - 60

3.17   Menu Tree   - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  61

3.18  Setup Menu 

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62

3.19  Hardware Adjustment and LEDs   - - - - - - - - - - - - - - - - - - - - - - - - -  63

4  Calibration  - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  64

4.1  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

Summary of Contents for X-3000ce-UW

Page 1: ...Version 2 0 Pub date 1 3 02 v11 PID Web Tension Controller INSTALLATION AND OPERATING INSTRUCTIONS X 3000ce UW...

Page 2: ......

Page 3: ...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 Ex...

Page 4: ......

Page 5: ...er 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...

Page 6: ...isplayed 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 Montalvo brake 50 20 80 10...

Page 7: ...ion 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...

Page 8: ...N 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...

Page 9: ...0 100 0 MAN UA L A UTO TENSIO N OFF ON AUTO M A N U A L OU TPU T 50 20 80 100 0 Type X3000 ce UW SN 3455 Supply voltage 115 230V 60 50Hz Supply current 0 5A IL007 dsf IL140 dsf 1 2 3 4 5 6 7 8 9 10 11...

Page 10: ......

Page 11: ...7 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 148 mm 120 mm 55 mm PE L N R1 R2 R3 R4 R5 R6 Enter Back Space Down Up DO 4...

Page 12: ...e 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 m...

Page 13: ...echanical Installation 1 3 02 13 3 1 2 X 3000 ce UW Cabinet Figure 1 mount standard For other mounting brackets consult factory Fig 1 18 18 Fig 2 20 4 5 Fig 3 Fig 4 IL037 dsf Cutout dimensions 320 x 2...

Page 14: ...nd 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 v...

Page 15: ...ponents 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...

Page 16: ...ter see diagram below 1 2 3 5u 0 3u 4 PR003 dsf 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54...

Page 17: ...at stop and open at start of operation see Fig 1 R1 R2 R3 R4 R5 R6 En t er B a ckS pace D ow n U p DO 4 DO 3 DO 2 DO 1 DI 8 DI 7 DI 6 DI 5 DI 4 DI 3 DI 2 DI 1 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 1...

Page 18: ...ain 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...

Page 19: ...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...

Page 20: ...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 repea...

Page 21: ...4 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 tim...

Page 22: ...e 115 230 V AC Current 200 mA S nr 3000 230 115 L N 44 45 18 19 20 47 48 49 10 K Auto setpoint 10 K Manual setpoint Voltage 0 10 V TENSION output 46 L N Power supply 115 230 VAC 34 36 6 Softstart Anti...

Page 23: ...Type 2 connector 6 pole DIN std 1 3 b l a c k w h i t e r e d 14 12 13 Multi cable Multi connector 10 K Manual 10 K Auto setpoint 10V GND 10V GND Tension Off GND 10V 24V Output Tension 100 K 100 K Fr...

Page 24: ...0 K 100 K Front panel 4 5 17 19 23 12 13 1 27 28 Multi connector 14 OPTIONS 10 K Manual 10 K Auto setpoint 10 K Splice Level 10V GND 10V GND 10V GND Tension Off Second Cal GND 10V 24V OPTIONS Output T...

Page 25: ...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 b...

Page 26: ...O4 Range 3 0VDC Manual DI1 Tension OFF DI3 24V 24V Softstart DI5 Brake 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 20mA Regulator o...

Page 27: ...Connection for T Series Idler Live Head UPB Connection for N Series Load Cells 11 12 13 14 15 16 17 40 41 42 43 44 45 46 RED WHITE BLACK LOAD CELL 1 CABLE 0VDC 2 5V 2 5V INPUT 0VDC 2 5V 2 5V INPUT Co...

Page 28: ...o Dn Level Up Level Range Time Brake Menu Range Dia Menu Dia Menu Diamet Src P Rev Roll mm Pulse Min Diam Max Diam Fac Diam DF AutoSet New Roll D Diameter Output2 Menu Out2 Src Out2 Slope Out2 Scale O...

Page 29: ...Max R1 R2 R3 R4 R5 R6 Enter Back Space Down Up DO 4 DO 3 DO 2 DO 1 DI 8 DI 7 DI 6 DI 5 DI 4 DI 3 DI 2 DI 1 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 44 45 46 47...

Page 30: ...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 Leve...

Page 31: ...gital Input Standard Functions 1 3 02 31 Cycles SOFTS TIME Run mode Stop mode Speed Time Run mode Machine 0 100 Controller output 100 0 Time HOLD LEVEL Fig 1 Fig 2 STORED LEVEL SOFTS LEV Hold mode SD0...

Page 32: ...in Anti Slope Splce Menu Splice Src Splice Del Splice Lev Splice Tim WebBr Menu Webbr Lev Webbr Time Range Exp RE Source Ranges Start No Dn Level Up Level Range Time Brake Menu Range Dia Menu Dia Menu...

Page 33: ...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 inc...

Page 34: ...ill 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 rol...

Page 35: ...de Menu Run Mode Amplifier 0 4mA Language Gain Ratio P Level D Level Softs Menu Start Out Softs Lev Softs Time Hold Level Anti Menu Anti Src Anti Max Anti Min Anti Slope Splce Menu Splice Src Splice D...

Page 36: ...t 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 Diagnos...

Page 37: ...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 internal...

Page 38: ...ment has been made in step e return to step b Anti min 20 Anti min 30 Anti min 0 Controller output 100 80 60 40 20 0 20 40 60 80 100 Anticoast Torque Anticoast min C G002 dsf Diagnostic Password Setup...

Page 39: ...f If adjustment has been made in e return to step b Diagnostic Password Setup Menu Mode Menu Run Mode Amplifier 0 4mA Language Gain Ratio P Level D Level Softs Menu Start Out Softs Lev Softs Time Hol...

Page 40: ...reat 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...

Page 41: ...Start Out Softs Lev Softs Time Hold Level Anti Menu Anti Src Anti Max Anti Min Anti Slope Splce Menu Splice Src Splice Del Splice Lev Splice Tim WebBr Menu Webbr Lev Webbr Time Range Exp RE Source Ran...

Page 42: ...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...

Page 43: ...sion 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 a...

Page 44: ...Mode Amplifier 0 4mA Language Gain Ratio P Level D Level Softs Menu Start Out Softs Lev Softs Time Hold Level Anti Menu Anti Src Anti Max Anti Min Anti Slope Splce Menu Splice Src Splice Del Splice Le...

Page 45: ...t 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 TERM...

Page 46: ...tentiometer Use 10 k 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 Refe...

Page 47: ...oltage 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...

Page 48: ...gh See Fig 1 Diagnostic Password Setup Menu Mode Menu Run Mode Amplifier 0 4mA Language Gain Ratio P Level D Level Softs Menu Start Out Softs Lev Softs Time Hold Level Anti Menu Anti Src Anti Max Anti...

Page 49: ...prevent small tension drops stopping the machine short enough to prevent minimum material waste before stop START STOP DO1 Web break 1 2 3 4 5 6 7 8 9 10 30 31 32 33 34 35 36 37 38 39 K100 1 COM 2 NC...

Page 50: ...ssible 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 lo...

Page 51: ...ange 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...

Page 52: ...o Dn Level Up Level Range Time Brake Menu Pads R1 Pads R2 Pads R3 Pads R4 Randomize Range Dia Menu 4 3 Dia 3 2 Dia 2 1 Dia Dia Menu Diamet Src P Rev Roll mm Pulse Min Diam Max Diam Fac Diam DF AutoSet...

Page 53: ...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 condition...

Page 54: ...ting 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...

Page 55: ...r 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...

Page 56: ...er 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 followi...

Page 57: ...LOG 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...

Page 58: ...r 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...

Page 59: ...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 Scrol...

Page 60: ...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...

Page 61: ...ode Amplifier 0 4mA Language Gain Ratio P Level D Level Softs Menu Start Out Softs Lev Softs Time Hold Level Anti Menu Anti Src Anti Max Anti Min Anti Slope Splce Menu Splice Src Splice Del Splice Lev...

Page 62: ...onal 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 Subm...

Page 63: ...8 0 0 DO 4 DO 1 DO 2 DO 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 L N PE TENSION 45 Type X D 3100 Serial no 960034 V...

Page 64: ...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 sur...

Page 65: ...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...

Page 66: ...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...

Page 67: ...7 0 0 3 0 Splce Menu Splice Src NONE Splice Del 0 2 0 0 1 0 S Splice 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 NONE Ranges 1 1 4...

Page 68: ...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...

Page 69: ...ew roll starting output after splice Power Diode The green LED indicates that the unit is on 50 20 80 100 0 MAN UA L A UTO TENSIO N OFF ON AUTO M A N U A L OU TPU T 50 20 80 100 0 Type X3000 c e UW SN...

Page 70: ...49 1 48 1 47 1 52 1 51 1 50 Splice input Manual setpoint Manual input AI4 Splice input AI5 Optional analog output 0 10V 1 57 Analog output AO4 10V 1 27 1 25 1 24 Diameter input x1 x10 ZERO R4 R5 CAL 1...

Page 71: ...tor 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...

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Page 74: ...rham Maine 04038 USA Email info montalvo com www montalvo com Tel 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 no...

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