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Montalvo X-3000ce-N Installation And Operation Instructions Manual

Pid web tension controller
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INSTALLATION AND OPERATION INSTRUCTIONS
X-3000ce-N
PID Web Tension Controller
Version 1.0 Pub. date: 9/23/02 v2

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  • Page 1 INSTALLATION AND OPERATION INSTRUCTIONS X-3000ce-N PID Web Tension Controller Version 1.0 Pub. date: 9/23/02 v2...

  • Page 3: Table Of Contents

    4.3 Regulation Parameter, Gain, Ratio - - - - - - - - - - - - - - - - - - - - 55 5 Operating the X-3000ce-N - - - - - - - - - - - - - - - - - - - - - - 56...

  • Page 5: General Description

    (please refer to the diagram on the following page). The control outputs of 4 to 20 mA and 0 to 10 volts DC enable the X-3000ce-N to interface with a variety of variable speed drives to control web tensioning motors.
  • Page 6 1 General Description Manual Mode Function (Open Loop) There is no tension regulation in the manual mode. The speed of the NIP motor follows the actual line speed plus or minus the amount of manual trim that has been selected. X3000ce-N controller MANUAL AUTO...
  • Page 7 General Function and Standard Operation MANUAL AUTO TAPER % TRIM % 100% -100 +100 100% MANUAL/ MATERIAL LOW/ OPTION: TRIM % HIGH AUTO SELECT -Taper % -Material 1 / 2 -Cal. low/high IL123.dsf 1. Manual Trim% Supplies a trim level (+/-) to the line speed when the controller is running in manual. In auto mode, the controller automatically regulates output so that actual tension 2.

  • Page 8: Technical Data

    2 Technical Data 2 Technical Data 2.1 X-3000ce-N Electrical AC Input 115 or 230 VAC +10% (ENG 60204) 48 to 62 Hz 115 V-160 mA T (slow-blowing type) Ø5 x 20 mm Fuse Size (fuse not installed by factory) 230 V-80 mA T (slow-blowing type) Ø5 x 20 mm...

  • Page 9: X-3000Ce-Uw-N Mechanical

    2.2 X-3000ce-N Mechanical 2.2 X-3000ce-N Mechanical Dimensions (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"...

  • Page 11: Lnstallation And Setup

    3 Installation and Setup 3 Installation and Setup 3.1 Mechanical Installation 160 mm Type : X-3000ce-UW 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 DI 6...
  • Page 12 Avoid mounting the controller cabinet close to drive controllers or any The X-3000ce-N controller cabinet should be mounted in a dry place, away from any other equipment that source of heat. The mounting surface should be free of any excessive vibration. If...
  • Page 13 3.1 Mechanical Installation 3.1.2 X-3000ce-N Cabinet 18° 18° Fig. 2 Fig. 1 Cutout dimensions: 320 x 250 mm IL037.dsf Fig. 4 Fig. 3 9/23/02...

  • Page 14: Electrical Installation

    3 Installation 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.

  • Page 15: Quick Setup Guide

    3.3.1 Introduction help get the system up and running in a short The controller system will typically include the following components: period of time. • 1 X-3000ce-N To maximize system • 1 motor controller performance, please • 1 motor read the entire manual.
  • Page 16 3 Installation and Setup 3.3.3 Electrical Installation 1. Line speed signal Connect cable from X-3000ce-N controller to the source of the line speed signal (see diagram below): X3000-ce-N Linespeed 0 - 10 VDC 0 - 10 VDC Output (max. 20 VDC)
  • Page 17 Section 3.6, "Basic Wiring Instructions‚" p. 29. Connection of start/stop signal from machine main panel: Connect cable between the start relay of the NIP motor controller and X-3000ce-N. The signal must come from a relay with the following function: a) The relay must: •...
  • Page 18 CONTROLLER Connection of supply voltage to the X-3000ce-N controller Connect cable between machine main panel and X-3000ce-N 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 19 3.3 Quick Setup Guide Connect cable in the X-3000ce-N (see diagram below). Voltage Switch ( In 230 v Position ) Type : xxxxxxxxxx Serial no : xxxxxxxx Voltage : xxxxxxxxx Current : xxxxxxx Fuse Holder R1 R2 DO 4 DO 3...
  • Page 20 3 Installation and Setup 3.3.4 Web Tension Adjustment 1. Check that load cells are mounted and oriented properly. Refer to the load cell For cabinet and non- installation instructions. cabinet versions of 2. Before applying power, check that tension meter is mechanically zeroed. If not, the controller, see adjust the small screw below the meter scale until the meter reads zero.
  • Page 21 3.3 Quick Setup Guide 7. Adjust potentiometer R2 until analog meter reading is identical to the hanging Diagnostic weight. (If non-cabinet version is used, see digital display: tension will appear as Version a percentage value [%]). Run Mode Tension Dancer Setpoint Output I-Level...
  • Page 22 3 Installation and Setup 3.3.5 Startup and Adjustment Run Mode Status Menu 1. Choose the application under [Mode Menu][Run Mode] Material Ver NIP Tension • Load cell infeed = [X-INF] Setpoint • Load cell outfeed = [X-OUTF] Output Summation Output2 Trim Out Diameter Load cell...
  • Page 23 3.3 Quick Setup Guide 6. Increase line speed in increments until maximum speed is reached. Check that Run Mode [Trim Out] regulates at approximately 0%. If [Trim Out] value Status Menu Material fluctuates above 25% or below 0%, adjust R6 gradually until the regulation Ver NIP approaches 0%.
  • Page 24 3 Installation and Setup 3.3.6 Basic Diagrams for Standard Application Non-cabinet version Type : X-3000P-ce-N Serial no : 1500 Voltage : 115V/230V AC Current : <200 mA TENSION 45 % DO 4 DO 3 DO 2 DO 1 Back Space DI 8 DI 7 DI 6...
  • Page 25 3.3 Quick Setup Guide Cabinet Version MANUAL AUTO TRIM % 100% -100 +100 MANUAL / TRIM % AUTO Type: X3000-c e-UW SN: 3455 Supply voltage: 115/230V 60/50Hz Supply current: <0.5A IL121.dsf Wiring Diagram Front panel Auto Manual Tension setpoint Trim % Trim % 10 K 10 K...

  • Page 26: Complete Wiring Diagram

    3 Installation and Setup 3.4 Complete Wiring Diagram Front panel OPTIONS OPTIONS Auto Manual Taper % Tension setpoint** Trim %** Trim % 10 K 10 K 10 K Second Man / Material Cal.** Auto** 1 / 2** Multi connector Type : X-3000-P-ce-N Serial no : 960034 Voltage : 115V/230V AC...
  • Page 27 3.4 Complete Wiring Diagram MANUAL AUTO TAP E R % TRIM % -10 0 +10 0 100% 100% MANUAL / MATERIAL LOW/ TRIM % OPTION: AUTO SEL ECT HIGH -Taper % -Material 1 / 2 -Cal. low/high ** Analog signals (Manual trim% and Auto Setpoint) and digital signals (Man/Auto, Material 1/2 and Second cal.) can only be used one place at a time.

  • Page 28: Terminal Blocks

    3 Installation and Setup 3.5 Terminal Blocks 4-20mA output Input for 4-20mA U/I converter 0VDC Trim% Ouput +/-10V +10V 0VDC -10V Trim% Input +/-10V Diameter input Line speed Input 0-20V 0VDC 0VDC Calibrated Diameter (output) +10V Taper input 0-10 VDC Splice input (not used) 0VDC 0VDC...

  • Page 29: Basic Wiring Instructions

    3.6 Basic Wiring Instructions 3.6.1 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 0 - 10 VDC Trim Setpoint 0 - 100% 0 - 100% WD099.dsf Tension Wiring Diagram from line speed Source to the X-3000ce-N Type : X /D-3000 Serial no : 960034 Volt age : 115V /230V AC Current : <200 mA TENSION...
  • Page 31 Maximum load: 5 mA. Typical connection of motor controller Connect the regulated output from the X-3000ce-N to the speed setpoint on the NIP motor controller. Set the torque from either 1) an analog input with an external source or 2) the motor controller menu, depending on the type of motor controller being used (see wiring diagram below).
  • Page 32 3 Installation and Setup 3.6.3 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 33: Digital Input: Standard Functions

    3.7 Digital Input: Standard Functions 3.7 Digital Input: Standard Functions 3.7.1 Start (Terminal 34) Start and stop the regulator with this input. Output signal (terminal 17) will follow the If terminal 34 = low (OVDC): linespeed. (Output=Linespeed) Output signal (terminal 17) will regulate with a +/- trim signal [approximate to] the If terminal 34 = high (+24VDC): linespeed.
  • Page 34 3 Installation and Setup Run Mode Status Menu Material Ver NIP R U N Tension After start signal goes high Setpoint (+24 VDC), enter a delay Output Start Del Summation before the controller begins Output2 to regulate: Trim Out Diameter Password Start delay Setup Menu...
  • Page 35 3.7 Digital Input: Standard Functions 3.7.2 NIP Open (D12) (Terminal 2) Run Mode Status Menu Material This signal indicates to the controller whether the nip is open or closed (see picture Ver NIP below). An open nip cannot be regulated. The function on Nip Open (terminal 2) Tension depends upon whether start (terminal 34) is high (+24 VDC) or low (0 VDC).
  • Page 36 3 Installation and Setup The following sequence diagrams show Open Mode from 1) HOLD and 2) RESET. Run Mode Status Menu Material 1. Open Mode = HOLD under the Nip Menu: Ver NIP Tension Setpoint Output 100 % Linespeed (Ref. Speed) Summation Output2 Trim Out...
  • Page 37 3.7 Digital Input: Standard Functions 2. Open Mode = RESET under the Nip Menu: Run Mode Status Menu Material Ver NIP Tension 100 % Setpoint Linespeed (Ref. Speed) Output Summation Output2 Trim Out 50 % Diameter Password Setup Menu Mode Menu Run Mode Trim Menu Trim On/Off...
  • Page 38 3 Installation and Setup Electrical Wiring Run Mode Status Menu Material Here is a typical example of how to connect the Nip Open signal. Ver NIP Tension Setpoint Output WD039.dsf Summation Output2 NIP OPEN Trim Out Diameter Password Setup Menu +24V Mode Menu Run Mode...
  • Page 39 3.7 Digital Input: Standard Functions 3.7.3 Material 1 or 2 Options (DI3) (TERMINAL 32) Run Mode Status Menu Use this digital input to change between 2 different parameter settings. Typically this Material Ver NIP is used when a machine is running both elastics and non-elastic material. Tension Setpoint Electrical Wiring...

  • Page 40: Analog Signals: Standard Functions

    3 Installation and Setup 3.8 Analog Signals: Standard Functions Auto Setpoint Potentiometer Connects to the CCW terminal (1) of the AUTO potentiometer. Use 10 k Ω 0VDC potentiometer. 0 to 10 volt input corresponding from zero to full scale tension in AUTO mode. 19 Auto setpoint Connects to the wiper terminal (2) of the AUTO potentiometer.

  • Page 41: Input And Output: Special Functions

    3.9 Input and Output: Special Functions 3.9 Input and Output: Special Functions 26 -10 V Reference Reference supply for external use. -10V max 5mA. 27 +10 VDC Reference Reference supply for external use. +10V max 5mA. 28 0 VDC For current output. Output from voltage to current converter.

  • Page 42: Digital Output

    3 Installation and Setup 3.10 Digital Output Run Mode Status Menu Material 3.10.1 Tension Low (D01) (Terminal 38) Ver NIP Tension Setpoint Tension Low either stops the machine in cases of web break or activates an alarm. Output Summation Electrical Wiring Output2 Trim Out Diameter...
  • Page 43 3.10 Digital Output 3.10.2 High Tension (D02) (TERMINAL 9) Run Mode Status Menu Material High Tension stops the machine in cases in which tension either goes too high or Ver NIP in which an alarm is needed. Tension Setpoint Electrical Wiring Output Summation Output2...
  • Page 44 3 Installation and Setup 3.10.3 LS Level (D03) (Terminal 39) Run Mode Status Menu Material LS Level is activated (i.e., goes high +24 VDC), when the line speed is above the Ver NIP parameter LS Level. The output signal indicates when the machine starts to move, Tension and can be used to activate Start on Terminal 34.

  • Page 45: Trim Menu

    3.11 Trim Menu 3.11 Trim Menu Trim Menu Trim On/Off Set up the controller system with the trim menu. Following are descriptions of the Trim Out parameters for Trim. Offset Trim Max Electrical Wiring Trim Min Connection of Trim On/Off Linespeed 0 - 20 VDC 0 - 10 VDC...

  • Page 46: Pid Menu

    3 Installation and Setup 3.12 PID Menu PID Menu SystemGain The PID Menu sets up the regulation parameters. The new parameters for this menu P Level are as follows: D Level Parameter Description For setting up SystemGain. Adjust this parameter to SystemGain optimize the regulation in the closed loop system.
  • Page 47 3.13 Surface Rewinder Options Electrical Wiring Example of analog diameter signal connection: Fig. 1 WD149.dsf +10V Diameter input 0 - 9V Diameter input 0 - 9V Example of Taper% connection: Zero offset R5 Scale +10V Diameter input AI6 Diameter to microprocessor input 0VDC Diameter calibrated...
  • Page 48 3 Installation and Setup Parameter Setting and Adjustment Run Mode Status Menu Parameter Description Adjustment Material 1. Scroll to Status Menu, then to Ver NIP Diameter. Tension Setpoint 2. Apply analog input for minimum Output diameter. Summation Output2 3. Adjust potentiometer R4 (offset) until Trim Out 0% is displayed.

  • Page 49: Operation Of The Controller Menu

    3.14 Operation of the Controller Menu 3.14 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 50 3 Installation and Setup 3.14.1 Menu for Run Mode Run Mode Status Menu Main menu Submenu Description Enter Material Ver NIP Displays actual running mode for the Run Mode Tension controller. Setpoint Output 3.14.2 Menu for Status Summation Output2 The status menu shows the different analog inputs to the operator. Trim Out Main menu Submenu Description...

  • Page 51: Setup Menu

    3.15 Setup Menu 3.15 Setup Menu Main menu Submenu 1 Submenu 2 Description Enter* Setup Main menu (accessed by password 5). Mode Menu To select the type of nip. Run Mode Submenu for setup of the trim signal. Enter this menu to change Trim Menu parameters.

  • Page 52: Menu Tree

    3 Installation and Setup 3.16 Menu Tree Run Mode Status Menu Material Ver NIP Tension Setpoint Output Summation Output2 Trim Out Diameter Password Setup Menu(behind password 5) Mode Menu Run Mode Trim Menu Trim On/Off Trim Out Offset Trim Max Trim Min PID Menu SystemGain...

  • Page 53: Hardware Adjustment And Leds

    3.17 Hardware Adjustment and LEDs 3.17 Hardware Adjustment and LEDs Adjusts to zero in the absence of web tension (tare adjustment) (see R1 Zero Range tension calibration procedure in Section 4.1, "Tension Calibration‚" p. 54). R2 Calibration Range Adjusts to show actual web tension. Adjusts to show actual web tension on the high scale during use of a R3 Calibration Range second calibration range.

  • Page 54: Calibration

    4 Calibration 4 Calibration 4.1 Tension Calibration 1. Check that load cells are mounted and oriented properly. Refer to the load cell For cabinet and non- installation instructions. cabinet versions of the controller, see 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.

  • Page 55: Tuning

    4.2 Tuning 7. Adjust potentiometer R2 until analog meter reading is identical to the hanging Diagnostic weight. (If non-cabinet version is used, see digital display: tension will appear as Version a percentage value [%]). Run Mode Tension Dancer Setpoint Output I-Level IL006.dsf Manual...
  • Page 56 4 Calibration 9. Readjust setpoint and check that actual tension approaches it. If the regulation Run Mode reacts too quickly or slowly, adjust SystemGain in the PID menu . (See Status Menu section 3.12) Material Ver NIP 10. Run machine in increments up to the maximum speed and check that Trim Tension Out is regulating around 0%.

  • Page 57: Operating The X-3000Ce-N

    5 Operating the X-3000ce-N 5 Operating the X-3000ce-N Actual Tension Displays actual tension on a scale of 0 to 100%. Actual Trim Output Indicates regulated trim output. Trim output (+/-) corrects the line speed so that actual tension reaches the tension setpoint. Trim output appears as -100 to 100% on the analog meter.

  • Page 58: Troubleshooting

    6 Troubleshooting 6 Troubleshooting Filter WD143.dsf 9/23/02...
  • Page 59 6 Troubleshooting If use of the X-3000ce-N 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 Tel. +45 75 57 27 11...
  • Page 62 The Montalvo Corporation • 50 Hutcherson Drive, Gorham, 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 notice. Printed in U.S.A. X-3000ce-N © 2001 MONTALVO...

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