Montalvo X-3100ce-RW Installation And Operation Instructions Manual
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Montalvo X-3100ce-RW Installation And Operation Instructions Manual

Pid web tension controller
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Better Web Control
INSTALLATION AND OPERATION INSTRUCTIONS
X-3100ce-RW
PID Web Tension Controller
Version 3.2 Pub. Date 10/6/03 v1

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Summary of Contents for Montalvo X-3100ce-RW

  • Page 1 Better Web Control INSTALLATION AND OPERATION INSTRUCTIONS X-3100ce-RW PID Web Tension Controller Version 3.2 Pub. Date 10/6/03 v1...

  • Page 3: Table Of Contents

    Table of Contents 1 GENERAL DESCRIPTION 2 TECHNICAL DATA 2.1 X-3100- LECTRICAL 2.2 X-3000- ECHANICAL 2.3 RS-232 C OMMUNICATIONS ACKAGE PTIONAL 2.4 F IELDBUS OMMUNICATIONS ACKAGE PTIONAL 3 INSTALLATION AND SETUP 3.1 M ECHANICAL NSTALLATION 3.2 E LECTRICAL NSTALLATION 3.3 Q UICK ETUP UIDE...

  • Page 5: General Description

    To properly set up and operate the X-3100ce-RW 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).
  • Page 6 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-3100ce-RW can quickly compensate for speed and diameter changes, and for other factors that affect tension during the process.
  • Page 7 1. General Description General Function and Standard Operation Cabinet version MANUAL AUTO 100% 100% 100% MANUAL/ TENSION OUTPUT AUTO OFF/ON OPTION: -Cal. low/high IL308-X310-RW-US 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 1.

  • Page 8: Technical Data

    2.1 X-3000-ce Electrical 2 Technical Data 2.1 X-3100-ce Electrical AC Input 115 or 230 VAC +10% (IEC TC77B WG3) 48 to 62 Hz 115 V-160 mA T (slow-blowing type) Ø5 x 20 mm 230 V-80 mA T (slow-blowing type) Ø5 x 20 mm Fuse Size (fuse not installed by factory) (Both types are supplied) II (IEC 664)

  • Page 9: X-3000-Ce Mechanical

    2.2 X-3000-ce Mechanical 2.2 X-3000-ce Mechanical 330 x 260 x 163 mm (12.99" x 10.23" x 6.43") Dimensions (L x W x H) (Cabinet version) 4.7 kgs (10.38 lbs.) Weight (Cabinet version) Dimensions L x W x H (non-cabinet version) 160 x 160 x 55 mm (6.3"...

  • Page 10: Rs-232 Communications Package (Optional)

    2.3 RS-232 Communications Package (Optional) 2.3 RS-232 Communications Package (Optional) xxx3100Pce-xx xxx3100ce-xx Ty pe : xx x3100Pc e-UW Volt age : 115 / 230 V AC Curr ent : <200 m A S. nr. 3000 AU T O M A N U AL SP LI C E 100% 100%...

  • Page 11: Fieldbus Communications Package (Optional)

    2.4 Fieldbus Communications Package (Optional) 2.4 Fieldbus Communications Package (Optional) xxx3100Pce-xx-XX xxx3100ce-xx-XX Type : x xx 3100Pce-UW Voltage : 115 / 230 V AC Current : <200 mA S. nr. 3000 M A N U AL AU TO S PL I CE 1 0 0 % 100% O UTP U T...

  • Page 12: Installation And Setup

    3.1 Mechanical Installation 3 Installation and Setup 3.1 Mechanical Installation 167 mm 10 mm Type : X-3100Pce-RW Voltage : 115 / 230 V AC Current : <200 mA S. nr. 3000 Tension DO 4 DO 3 DO 2 DO 1 Back Space DI 8 DI 7...
  • Page 13 3.1 Mechanical Installation Avoid mounting the controller 3.1.1 Cabinet cabinet close to The controller cabinet should be mounted in a dry place, away from any drive controllers source of heat. The mounting surface should be free of any excessive or any other vibration.
  • Page 14 3.1 Mechanical Installation 3.1.2 X-3000-ce-RW Cabinet Figure 1 mount standard. For other mounting brackets, consult factory. 18° 18° Fig. 2 Fig. 1 Cutout dimensions: 320 x 250 mm IL037.dsf Fig. 4 Fig. 3...

  • Page 15: Electrical Installation

    3.2 Electrical Installation 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.

  • Page 16: Quick Setup Guide

    • 1 Motor controller system • 1 Rewinder motor performance, please read the entire manual. X-3100ce-RW MA NUEL AUT O TA PER 1 0 0 % 1 00 % 1 0 0 % OU TP UT MA NU EL /...
  • Page 17 3.3 Quick Setup Guide 3.3.3 Electrical Installation 1. Connection of line speed Connect the line speed signal from the machine to the motor controller. Typical it has to be connected on the “speed” setpoint. Please refer to the motor controller documentation. (See example below): Example on a typical motor controller Motor Current...
  • Page 18 CABLE -2.5V 0VDC WD301-XDTI310-ALL-US *Colors refer to standard cables supplied by Montalvo 4. Connection of Rewinder and Machine Start signals : Connect cable from controller to the rewinder and the main panel. Connect the signals as decribed in the following.
  • Page 19 3.3 Quick Setup Guide 5. Connection of supply voltage to the controller. Connect cable between machine main panel and the 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.
  • Page 20 3.3 Quick Setup Guide For cabinet and 3.3.4 Tension Adjustment noncabinet versions of the 1. Check that load cells are mounted and oriented properly. Refer to controller, see the load cell installation instructions. section 2.2, p. 7. 2. Before applying power, check that tension meter is mechanically zeroed.
  • Page 21 3.3 Quick Setup Guide Diagnostic 7. Adjust potentiometer R2 until analog meter reading is identical to Version the hanging weight. (If non-cabinet version is used, see digital Run Mode display: tension will appear as a percentage value [%]). Tension Setpoint Output I-Level Manual...

  • Page 22: Startup And Adjustment

    3.4 Startup and adjustment Diagnostic 3.4 Startup and Adjustment. Password Setup Menu Mode Menu Rew Type Note: The Quick Setup Guide is intended to get the system up and Run Mode running in a short period of time. To maximize system performance, Amplifier Regulator Menu please read entire manual.
  • Page 23 3.3 Quick Setup Guide Diagnostic Password 12. Go to [Hold Menu] to adjust the time [Hold Delay] so that it Setup Menu fits to the machine’s deacceleration time. Mode Menu Rew Type • If signal for “start machine” (terminal 6) goes low before machine Run Mode Amplifier reaches zero speed, enter time between maximum and zero...

  • Page 24: Basic Diagrams For Standard Application

    3.6 Complete Wiring Diagram 3.5 Basic Diagrams for Standard Application Non-cabinet Version Type : xxx3100Pce-RW Voltage : 115 / 230 V AC Current : <200 mA S. nr. 3000 Diagnostic DO 4 DO 3 DO 2 DO 1 Back Space DI 8 DI 7 DI 6...
  • Page 25 3.6 Complete Wiring Diagram Cabinet Version AUTO M ANU AL 100% 100% OUTPUT M ANU AL TENSION A UTO OFF/ON Type: X31 00-ce-RW SN: xxxx Supply volta ge: 115 /23 0V 6 0/5 0Hz Supply current: <0.5A IL220.dsf Front panel Auto Manual Taper...

  • Page 26: Total Wiring Diagram

    3.6 Complete Wiring Diagram 3.6 Total Wiring Diagram Front panel Front panel Front panel OPTIONS OPTIONS OPTIONS Auto Manual Taper** Tension setpoint** setpoint** Output 10 K 10 K 10 K 10 K 10 K 10 K 10 K 10 K 10 K Second Second...
  • Page 27 3.6 Complete Wiring Diagram MANUEL AUTO 100% 100% 100% MANUEL/ TENSION OUTP U T AUTO OFF /ON ** A nalog signals (manual setpoint and taper) 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.

  • Page 28: Terminal Blocks

    3.8 Basic Wiring Instructions 3.7 Terminal Blocks Output 4-20mA from U/I converter Input 0 - 10 VDC for U/I converter 0VDC Analog Output2 0-10V +10V 0VDC -10V External gain 0-10V Diameter input 0 - 10 VDC (AI6) Line speed AI7 0-10V 0VDC 0VDC Taper output (AO1)

  • Page 29: 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.
  • Page 30 3.8 Basic Wiring Instructions 3.8.2 Installation: Regulated Output Common signal (GND) for regulated voltage or 15 OVDC current output. Connects to input ground of the converter or motor controller. 16 Regulated Regulated 4–20 mA current signal to an I/P or Current other converter.
  • Page 31 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. Supply Voltage Supply Voltage Ground...

  • Page 32: Digital Input: Standard Functions

    Montalvo Digital Input - Soft start 3.9 Digital Input: Standard Functions 3.9.1 Start Rewinder (terminal 34) This digital input is used to give the X3100ce the information when the rewinder is started or stopped. The information is used to control the mode of the X3100ce.
  • Page 33 3.9 Digital Input: Standard Functions Diagnostic Parameter Setting and Adjustment: Password Setup Menu Note: The rewinder has to be set up as rewinder type 3 in the parameter Mode Menu [Rew.Type] in the Mode Menu. Set the [Password] level to 5 to access Rew Type [Setup Menu] .
  • Page 34 3.12 Web break 3.9.2 Start Machine (terminal 6) This digital input is used to give the X3100ce the information when the machine is started or stopped. The information is used to control the mode of the X3100ce. When the rewinder is started it will run in auto mode or if tension level is reached it will be changed to hold mode.
  • Page 35 3.9 Digital Input: Standard Functions Diagnostic Parameter Setting and Adjustment Password Setup Menu 1. [Dyn.Factor] (Dynamic compensation factor) Mode Menu The dynamic compensation is generated according to the curve shown Rew Type Run Mode below. A scaling factor called [Dyn.Factor]is then used to scale the Amplifier curve up or down in size.
  • Page 36 3.12 Web break Diagnostic 3. [Hold level] (Hold level) Password When start machine is deactivated the X3100ce stores the output level, but Setup Menu continues to regulate until the [Hold Delay] has run out. If the time is set Mode Menu to the minimum value of 0.1 seconds, the output will change to hold level Rew Type Run Mode...
  • Page 37 3.9 Digital Input: Standard Functions 3.9.3 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. 3.9.4 Tension Off (DI3) (TERMINAL 32) When activated by a 24 VDC input, the output goes to zero and the regulator is reset.

  • Page 38: Analog Signals: Standard Functions

    3.10 Analog Signals: Standard Functions 3.10 Analog Signals: Standard Functions Manual Potentiometers Connects to the CCW terminal (1) of the MANUAL 47 0VDC potentiometer. Use 10 k potentiometer. 0 to 10 volt input corresponding from zero to 48 Manual maximum output in manual mode. Connects to the wiper terminal (2) of the MANUAL potentiometer.

  • Page 39: Input And Output: Special Functions

    3.9 Digital Input: Standard Functions 3.11 Input and Output: Special Functions Special Functions Input for voltage to current converter. Converts 58 Input 0-10V 0-10V into 4-20mA.on terminal 29. +10V max 5mA. Used in special applications. 57 Extra Analog Output2 For extra analog output. 56 0VDC Input for external gain reference to the regulator.

  • Page 40: Web Break

    3.10 Analog Signals: Standard Functions 3.12 Web Break This digital output can be used to 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 Start Machine is activated: This 10-second period allows startup with new rolls when little or no tension...
  • Page 41 3.15 Operation of the Controller Menu Diagnostic Electrical Wiring Password Provided below is a typical example of the web break connection. Setup Menu Mode Menu Rew Type Fig. 1 Run Mode START Amplifier Regulator Menu Gain Min. Gain Max. Sys. Gain Web break / P level D Level...

  • Page 42: Taper

    3.16 Menu Tree Diagnostic 3.13 Taper Taper is used to reduce web tension as the roll diameter increases. Taper is used to prevent roll telescoping or starring. Taper reduces the tension by an adjustable percentage (%) as the roll is building up (increasing diameter).
  • Page 43 3.13 Taper Parameter Setting and Adjustment Diagnostic Password [Taper Max.] Setup Menu This parameter sets the maximum tension reduction, which will be done at Mode Menu the maximum roll diameter, when TAPER is set to 100%. Typically it will be Rew Type set to 75 % (see diagram below).

  • Page 44: Diameter

    3.14 Diameter 3.14 Diameter The diameter is in some cases useful and necessary, such as in the following instances: • Control of gain, unwinder • Reduction of tension (taper) on rewinder • Control of stop level at fast stop, unwinder •...
  • Page 45 3.14 Diameter a) Roll 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.
  • Page 46 3.14 Diameter Electrical Wiring Figures 1 and 2 describe the proper connection of the analog diameter signal and the 2 proximity switches: Fig. 1 Fig. 2 +10V +24V Diameter input 0 - 10V Diameter +24 S 0V +24 S 0V input 0 - 10V Diagnostic Brake pulse...
  • Page 47 3.14 Diameter Diagnostic Password b) If [PULSE] is source, set up the following parameters: Setup Menu Mode Menu Rew Type [P/rev Roll] The number of pulses per revolution on the roll. Run Mode [mm/Pulse] Mm between pulses on the main machine. Amplifier Regulator Menu [Min Diam]...

  • Page 48: Operation Of The Controller Menu

    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.

  • Page 49: Menu Tree Diagnostic

    3.16 Menu Diagnostic 3.16 Menu Tree Diagnostic Main menu Submenu Description Diagnostic Main Menu Version Software version Run Mode Shows the actual Run Mode (see 3.17 below). Tension Analog input no. 2, tension -110% to 110% Setpoint Analog input no. 1, setpoint-110% to 110% Output Analog input no.

  • Page 50: Menu Tree

    3.18 Menu Tree 3.18 Menu Tree Diagnostic Taper Menu Password Taper min Setup Menu Taper max Mode Menu Webbr Menu Rew Type Webbr Lev. Run Mode Webbr Time Amplifier Dia. Menu Regulator Menu Diamet.Src Gain Min. P/Rev Roll Gain Max. mm/Pulse Sys.

  • Page 51: Setup Menu

    3.19 Menu Diagnostic 3.19 Setup Menu Submenu 2 Describtion Main Menu Submenu 1 Enter Main menu R Setup Menu Mode Menu Setup rewinder type. Rew Type Load cell unwind, X UW Run Menu x1 or x10 preamplifier Amplifier Submenu for regulator Regulator Menu parameters.

  • Page 52: Hardware Adjustment And Leds

    3.20 Hardware Adjustment and LEDs 3.20 Hardware Adjustment and LEDs Adjusts analog tension meter (or digital display) to zero with no load on the load cell (zero adjustment) R1 Zero Range (see tension calibration procedure in Section 4.1) Adjusts analog tension meter (or digital display) to R2 Calibration Range show actual web tension.

  • Page 53: Calibration

    4.1 Tension Adjustment 4 Calibration 4.1 Tension Adjustment Diagnostic 1. Check that load cells are mounted and oriented properly. Refer to Version the load cell installation instructions. Run Mode Tension 2. Apply power to the controller and let it warm up for at least 10 Setpoint minutes.

  • Page 54: Regulator Menu

    4.1 Tension Adjustment Diagnostic 6. Adjust potentiometer R2 until analog meter reading is identical to Version the hanging weight. (or see the digital display: tension will appear as Run Mode a percentage value [%]). Tension Setpoint Output I-Level Manual Splice IL006.dsf Line Speed Diameter...

  • Page 55: Tuning

    4.3 Tuning Diagnostic 4.3 Tuning Password Setup Menu Mode Menu Motor setup: Rew Type The motor and motor controller has to be setup and adjusted, before we Run Mode can run with the system. Please refer to the motor controller Amplifier documentation.

  • Page 56: Customer Parameter Settings

    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 Name: Parameter Factory Min. Max. UNIT Value: Setting: Mode Menu Rew Type Mode X-REW Amplifier Gain Min.

  • Page 57: Operation

    5 Operation 5 Operation Web Tension Meter Displays actual web tension from 0 to 100%. Scale as required for application. Output Meter Displays regulated output from 0 to 100%. Mode Switch - Auto/Manual Used to select either AUTOMATIC (closed loop) or MANUAL (open loop) mode of operation.
  • Page 58 5 Operation Power Diode The green LED indicates that the unit is on. AUTO M A N U A L 100% 100% M ANU AL TENSION OUTPU T A UTO OFF/ON Type: X3100-ce-UW SN: xxxx Supply volta ge: 115/23 0V 60/5 0Hz Supply current: <0.5A IL160.dsf...

  • Page 59: Troubleshooting

    6 Troublesshooting 6 Troubleshooting Note: Diagram shows all possible functions for this circuit board. Some, however, are either not used in this or are available only as options at an additional cost. Consult factory for further details.
  • Page 60 Motor too small, drive current limit set too low. Drive problem If use of the controller is no longer required, dispose of it according to regulations in force at the time. For service, please contact: The Montalvo Corporation Danarota Technic A/S 50 Hutcherson Drive GI. Skartved 5 DK...

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