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DFE SteadyWeb Instruction Manual

Automatic tension controller
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INSTRUCTION MANUAL
S
W
TEADY
EB™
AUTOMATIC TENSION CONTROLLER
DOC 801-0783

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  • Page 1 INSTRUCTION MANUAL TEADY EB™ AUTOMATIC TENSION CONTROLLER DOC 801-0783...
  • Page 2 TECHNICAL SERVICE - Installations, Start-Up, Troubleshooting, Repairs, Field Service, Returns: call 603-332-6150 and ask for Technical Support or email to us at techsupport@dfe.com CUSTOMER SERVICE - Replacement Parts, Individual Products, Questions about Orders, Manuals: call 603-332-6150 and ask for Customer Service or email to us at customerservice@dfe.com...
  • Page 3 READ THIS! ™ Your SteadyWeb Controller has been properly configured 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 4 - Calibration the Tension Meter...

  • Page 4: Table Of Contents

    PAGE General Description Output Modules, Version of Controller Pneumatic Output Module (12P) High Voltage Output Module (12V) 0-10 Volt Compensated Output Module (12D) SteadyWeb Controller Exploded View Specifications Standard Features 0-10 Volt Tension Output 4-20mA Tension Output Automatic Control Mode...
  • Page 5 SECTION TWO INSTALLATION OF STANDARD UNIT Dimensions Installing the Enclosure Electrical Connections Electrical Connections for Options SECTION THREE INSTALLATION OF H6 AND CC CONFIGURATIONS H6 Configuration Dimensions CC Configuration Dimensions Electrical Connections SECTION FOUR CALIBRATING THE TENSION METER Mechanical Zero Calibration SECTION FIVE SET-UP AND ADJUSTMENTS OF...
  • Page 6 Output Modules Fuses Ribbon Cables Relays Miscellaneous APPENDICES Locations of Standard Adjustments DIP Switch Settings Basic Set-up Electrical Connections of Standard SteadyWeb Electrical Connections of Options Transducer Electrical Connections Typical Tensions Front Board Troubleshooting TERMS AND CONDITIONS OF SALE 70,71 INDEX...
  • Page 7 LIST OF ILLUSTRATIONS FIGURE DESCRIPTION PAGE SteadyWeb Controller - Exploded View Front Panel and Operator Devices Dimensions Mounting Screw Locations Cover Removal Electrical Connections Electrical Connections of Options Remote Operator Device Configuration Dimensions of H6 Chassis Configuration (CC) Dimensions of CC Configuration...

  • Page 9: General Description

    The second function is the tension regulator. It compares the output signal from the transducers with the signal from the AUTO Set potentiometer on the front of the SteadyWeb enclosure. If there is a difference, the regulator will either increase or decrease tension to equalize them. The tension amplifier and the tension regulator are both located on the Control board.

  • Page 10: Steadyweb Controller - Exploded View

    STEADYWEB CONTROLLER EXPLODED VIEW Figure 1 - STEADYWEB CONTROLLER - EXPLODED VIEW...
  • Page 11 1.3 SPECIFICATIONS POWER INPUT 12P and 12D ..120/240 Volts 60/50Hz single phase @ 1 Amp 12V ... . 120/240 Volts 60/50Hz single phase @ 5 Amp OUTPUT 12P .
  • Page 12 Version 12D controllers having -10 to +10 volt outputs. ! POWER VOLTAGE SELECTION. The SteadyWeb controller is designed to operate on two ranges of AC power; 110-120 Volts 60/50 Hz, and 220-240 Volts 60/50 Hz. A slide switch on the Power...
  • Page 13 ! RATIO. Takes the sampled output and multiplies it (unwind applications) or divides it (rewind applications) by a factor adjustable between 1 and 10. Used in flying splice applications to help provide a match between controller output and roll diameter. ! REMOTE TENSION ON/OFF.
  • Page 14 1.5 OPTIONS (The option code is shown in parentheses) SOME OF THESE OPTIONAL FUNCTIONS REQUIRE CONFIGURING OR EXTERNAL WIRING. REFER TO SECTION 6 FOR CONFIGURING AND SECTION 2.3 FOR WIRING. ! 220 VOLT POWER (220V). 220 volt 50/60 Hz power input. ! 24 VOLT OUTPUT (24V).
  • Page 15 TI7. This allows use of special indicator functions, such as intrinsic safety, which are not available in the SteadyWeb controller. ! REVERSE OUTPUT (RO). Controller output goes up when tension exceeds the set point. This is the reverse of normal, when output goes down upon excess tension.

  • Page 16: Front Panel And Operator Devices

    1.6 FRONT PANEL AND OPERATOR DEVICES Figure 2 - FRONT PANEL and OPERATOR DEVICES...

  • Page 17: Dimensions

    SECTION 2 INSTALLATION 2.0 DIMENSIONS 12.44 10.42 7.75 1.42 2.41 11.78 9.41 10.54 4.71 inch Note: Allow 5" (127mm) clearance on the left side for the controller to open completely. FRONT SIDE BACK REMOTE PNEUMATIC ASSEMBLY DIMENSIONS inch Figure 3 - DIMENSIONS...

  • Page 18: Installing The Enclosure

    2.1 INSTALLING THE ENCLOSURE Select a location on the machine frame or a wall that will be convenient for the machine operator to operate the controller and to see the tension meter easily. Be sure the location is free of vibration, and is dry and clean. Take care to choose a place that the controller won't be struck and damaged by anything or anyone.

  • Page 19: Electrical Connections

    After removing the cover, swing the front panel out by first loosening the two screws on the right side top and bottom corners 1/4 turn CCW. Use a hex wrench to tighten the two enclosure mounting screws. 2.2 ELECTRICAL CONNECTIONS Refer to the drawing below for electrical connections.

  • Page 20: Electrical Connections For Options

    2.3 ELECTRICAL CONNECTIONS OF OPTIONS Figure 7 - ELECTRICAL CONNECTIONS OF OPTIONS...

  • Page 21: Installation Of H6 And Cc

    INSTALLATION OF H6 AND CC SECTION 3 CONFIGURATIONS In addition to the standard enclosure, all SteadyWeb controllers are available in two optional enclosure configurations, H6 and CC. These are normally used by OEMs who wish to integrate the controller into their own electrical enclosures.

  • Page 22: Dimensions

    DIMENSIONS OF H6 ENCLOSURE CONFIGURATION. 11.78 9.41 10.54 11.24 10.60 10.51 9.31 8.78 inch 8.09 .163 Dia .19 Dia 1.24 1.58 7.35 inch Typ 2 Typ 2 Figure 9 - DIMENSIONS OF H6 ELECTRICAL CONNECTIONS OF H6 CONFIGURATION. All electrical connections are made in the usual way at the standard terminal strips on the controller Power board.

  • Page 23: Cc Configuration

    3.1 CC ENCLOSURE CONFIGURATION The CC (Chassis Configuration) also uses the basic SteadyWeb enclosure with the cover omitted. The front panel is also omitted. So the user must provide all operator devices. A special cover plate takes the place of the front panel on the controller. An interface card is mounted on the cover plate.

  • Page 24: Electrical Connections

    ELECTRICAL CONNECTIONS OF CC 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 OF CC CONFIG. on INTERFACE BOARD...

  • Page 25: Electrical Connections Of Cc

    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: Calibrating The Tension Meter

    CALIBRATING THE TENSION METER SECTION 4 (See Section 6.4 to calibrate the optional Digital Meter) 4.0 MECHANICALLY ZERO THE TENSION METER This step is only necessary if the tension meter needle does not rest on 0 when the controller power is turned off. Push the POWER button to turn off power to the controller.
  • Page 27 Figure 14 - WEB PATH FOR METER CALIBRATION f) Attach the weight to the free end of the rope as shown above. Adjust the CAL A pot. as required to set the meter needle at the value of the weight. g) Remove the weight and observe the tension meter.

  • Page 28: Standard Features

    Almost all machines that process a continuous web have more than one tension zone. The SteadyWeb controller can be used in any tension zone, however it may need to be configured for the zone it will be used in. The information below will be used later to determine the correct configuration.

  • Page 29: The Control Board

    5.1 THE CONTROL BOARD Figure 16 - CONTROL BOARD...

  • Page 30: The Power Board

    5.2 THE POWER BOARD Figure 17 - POWER BOARD...

  • Page 31: Power Voltage Selection

    5.3 POWER VOLTAGE SELECTION (See Figure 17, page 22) The SteadyWeb controller is designed to operate on either 115v-60Hz or 230v-50/60Hz power. Select the correct voltage for your application with the Power Selector Switch, SW203. The left position selects 230v; the right position selects 115v.

  • Page 32: 4-20Ma Or 0-20Ma Output

    Measure voltage between test points TP117(+) and TP107. Adjust the -LIMIT pot. for 10 volts. d) Set the SW103 switches as required for the control voltage desired. For all SteadyWeb controllers having pneumatic (12P) or high voltage outputs (12V) set the switches as shown for the 0 to +10 volt output.

  • Page 33: Emergency Stop

    5.6 EMERGENCY STOP (See Page 4 for description, Figure 17 for switches) An external contact is required. The controller will be in the Emergency Stop mode as long as the contact is closed and will go to the AUTO mode as soon as it opens. No adjustments are required. Works in the MANUAL control mode, too.

  • Page 34: High Voltage Output Module (12V Only)

    5.7 HIGH VOLTAGE OUTPUT MODULE (SteadyWeb Version 12V only, description on Page 1) This module, called the V-OUT card, contains the SCR bridge and driver circuitry to produce the output voltage of the controller. It is designed to operate with either 115v or 230v input power and to produce 90vdc, 45vdc, 24vdc, or 180vdc outputs.

  • Page 35: Meter Damping

    b) Turn power on. Turn Tension on. Switch to MANUAL control mode. Turn the MANUAL pot. all the way counter-clockwise. Connect a voltmeter to the output terminals on the VOUT card. c) Turn both SPAN and OFFSET pots. fully clockwise. Observe the voltmeter and turn the OFFSET pot.(RT402) slowly counter-clockwise until the voltmeter reads 0.

  • Page 36: Output Meter

    Control board fully clockwise to enable full output. Adjust the M-SENS pot. so the output meter reads 100%. 5.12 PNEUMATIC OUTPUT MODULE (SteadyWeb Version 12P only) (See Figure 16 for adjustment, see Page 1 for description) The air pressure regulator is preset to 80psi (5,5 bar). No further adjustment is needed. Set the PNEU FS pot.(RT201) for 75 psi maximum output.

  • Page 37: Ratio Up/Down

    5.13 RATIO UP/DOWN (See Page 4 for description, Figure 16 for adjustments) NOTE: The Ratio function is not normally needed for most applications. Use it only if there is a large tension fluctuation during or directly after the splice. The output of the controller is locked (see Section 5.17 Sample and Hold following) and then multiplied or divided when an external contact is closed.

  • Page 38: Remote Tension On/Off

    5.14 REMOTE TENSION AMPLIFIER INSTALLED? (See Page 7 for description, Figure 16 for switches) The SW102 switches must be set for the presence or absence of the Remote Tension Amplifier option. Set the switches as shown to accept the tension signal from the amplifier inside the controller (local) or the remote amplifier.

  • Page 39: Soft Start

    5.17 SAMPLE AND HOLD (See Page 5 for description, Figure 16 for switches) The output of the controller is measured and then locked at the measured value upon the closure of an external contact. The output remains locked only as long as the contact is closed. The status light on the front panel will light when the output is locked.
  • Page 40 c) Set the SS TEN DLY pot. (RT115) for a short time delay before Soft Start actuates. This eliminates nuisance actuation if tension drops for only a short time. The range is about 0 to 3 seconds. Turn the pot. CW to increase the delay. There is no delay when leaving the Soft Start mode.

  • Page 41: Speed Follow

    3. Actuation by machine speed. This requires an optional DC Tachometer card or Pulse Tachometer card to provide a machine speed signal. Calibrate the card as described in Section 6 before proceeding with Soft Start set-up. a) Set the SW104 switches as follows: SW104 1 - Open 2 - NA...

  • Page 42: Tachometer Card Installed

    5.20 TACHOMETER CARD INSTALLED? (See Page 6 for description, Figure 17 for switch) A Tachometer Card, Pulse Tachometer Card, or a custom Tachometer card is used with the Taper option, Speed Follow, and one version of Soft Start. The SW201 switches must be set according to the presence or absence of the card.

  • Page 43: Transducer Voltage Switch

    Set the SW202 switch as follows 5VDC - Slide switch UP 10VDC - Slide switch DOWN Figure 25 - TRANSDUCER VOLTAGE SWITCH...

  • Page 44: 220 Volt Power

    SECTION 6 OPTIONS YOUR STEADYWEB CONTROLLER OPTIONS HAVE BEEN PROPERLY SET UP AT THE FACTORY. IT SHOULD NOT BE NECESSARY TO MAKE ANY CHANGES. USE THE INFORMATION IN THIS SECTION TO VERIFY THE SET UP OR TO MAKE MODIFICATIONS IF YOUR REQUIREMENTS CHANGE.
  • Page 45 The following procedure sets the outputs of the card to +10 volts at maximum machine speed. a) Set the SW201 switches on the Power board. Refer to Section 5.20. b) Be sure the tachometers are connected to the Power board terminal strip as shown below. Figure 27 - DC TACHOMETER CONNECTIONS WARNING!!! To prevent possible damage to the circuit card, set the SW702 and SW703 switches as shown BEFORE installing the card and BEFORE running the...

  • Page 46: Digital Meter

    e) Set the SW702 (LTACH) and SW703 (RTACH) switches to accommodate the voltages measured in step c) above. Both switches are set in exactly the same way. Use the chart below. If the machine was run at half speed, multiply the voltages by 2 and use those values for the switch-setting chart below.

  • Page 47: Digital Meter Card

    Figure 28 - DIGITAL METER DISPLAY Figure 29 - DIGITAL METER CARD a) Determine the maximum tension to be used. Refer to Specifications, Section 1.3, and select the next highest analog meter scale. b) Determine the number of decimal places for the display. Unless the full-scale tension is very high, it is best to use the maximum of decimal places.

  • Page 48: Dual Calibration

    d) Measure the input voltage to the digital meter at pin 1 (+) of socket J901 (S13), and test point TP904 (-) (TP4). e) Adjust the ZERO A pot. on the Control board for 10VDC at the points in d) above. f) Adjust the CAL ADJ pot.(TR901) (TR1) to set the Digital Meter to the full-scale value selected.

  • Page 49: Pulse Tach Option Card

    Figure 30 - PULSE TACH OPTION CARD b) Be sure the pulse tachs are connected to Power board terminal strip as shown below. Figure 31 - PULSE TACHOMETER CONNECTIONS WARNING!! To prevent possible damage to the circuit card, set the SW601 switches as shown below BEFORE installing the card and BEFORE running the machine! INITIAL SW601 SETTINGS 1 - Closed...

  • Page 50: Remote Tension Amplifier

    A two conductor cable supplies the 0-10VDC tension signal from the remote device to the SteadyWeb controller. The meter in the controller is fed from the remote device signal, and it is calibrated by the ZERO and CAL pots. in the remote device. Switch SW102 must be set to accept the tension signal from either the local amplifier or the remote one.

  • Page 51: Taper Adjustment On Front Panel

    SW102 SWITCHES LOCAL REMOTE 1 - Closed 1 - Open 2 - Open 2 - Closed 3 - NA 3 - NA 4 - NA 4 - NA NA = Not Applicable b) The remote tension signal usually comes into the controller via the pre-wired cable connector on the bottom of the enclosure.
  • Page 52 a) Set the SW501 switches to select between the local taper adjustment pot., located on the Taper card, and an optional pot. located on the controller front panel. SW501 SWITCHES On Taper Card Open Closed On Front Panel Closed Open Note: Switches 1 and 2 are not used.
  • Page 53 Figure 34 - TAPER RIDER OPTION CARD a) Connect the rider roll pot. or voltage source as shown below. Figure 35 - RIDER 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.

  • Page 54: Tls Option Card

    c) Cause the diameter sensor to output a voltage signal corresponding to the core diameter. Measure voltage between test points TP801 (+) and TP807. Adjust the SPAN pot. (RT801) for 10 volts DC. d) Cause the diameter sensor to output a signal corresponding to the full roll diameter. Measure the voltage between test points TP801 (+) and TP807.
  • Page 55 SW401 SWITCH Turn Off Tension Closed Open Leave Tension On Open Open Disable TLS Closed Latch TLS Relay Closed Do Not Latch TLS Relay Open Note: Switch 3 is not used. NA = Not Applicable c) If the Reset button is required, install it in the front panel and connect it as shown below. The Reset button is only required if the Latch function is ON.
  • Page 56 Figure 39 - TLS RELAY CONNECTIONS...

  • Page 57: Tuning Pots

    TUNING FOR RUNNING STABILITY 7.0 INTRODUCTION The procedures in this section apply to all versions of SteadyWeb controllers, used in all tension zones. Unlike most of the adjustments for standard features and options, tuning adjustments can not be preset at the factory for every application.
  • Page 58 7.2 TUNING PROCEDURE a) Be sure the tension meter is calibrated properly (see Section 4). The controller may be impossible to tune if the meter is not calibrated. b) Set the pots. as shown below. Most systems will run stably with these initial settings. On the pots; 0% is at the fully counterclockwise position and 100% is fully clockwise.
  • Page 59 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 to match the nip roll speed to the machine speed.
  • Page 60 REPLACEMENT PARTS SECTION 8 Listed with Dover Part Numbers 8.0 STANDARD CIRCUIT BOARDS Front board. 723-0023 Control board. 723-0012 Power board. 723-0001 8.1 OPTIONAL CIRCUIT CARDS DC Tachometer Card. 723-0101 Dual Transducer Input Card. 723-0089 Interface Card. 723-0278 (For CC version only) Pulse Tachometer Card.

  • Page 61: Tension Limit Switch

    8.6 RELAYS Power 105-0000 (on Power board) Tension Limit Switch 105-0019 (option), (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 12P only) Enclosure cover 323-0126...

  • Page 62: Control Board

    Appendix A: Location of Standard Adjustments CONTROL BOARD Figure 41 - STANDARD ADJUSTMENTS - CONTROL BOARD POWER BOARD Figure 42 - STANDARD ADJUSTMENTS - POWER BOARD...
  • Page 63 Appendix B: DIP Switch Settings The location of the setup instructions is listed after the switch number. O = Switch is Open C = Switch is Closed CONTROL BOARD Fig. 16 SW101 (pages 27, 33) Normal Output Reverse Output Speed Follow Off Speed Follow On Nip Roll Speed input Off Nip Roll Speed input On...
  • Page 64 TENSION LIMIT SWITCH CARD (option) Fig. 37 SW401 (page 47) Turn Off Control Output Leave Control Output On Disable TLS Latch ON Latch OFF V-OUT BOARD (High Voltage Output Module for Version 12V, only) Fig. 20 SW401 (page 26) POWER IN OUTPUT (VDC) 115 VAC 0 - 90...
  • Page 65 DC TACH CARD (option) Fig. 26 SW701 (page 37) LTACH If 55 is + If 53 is + RTACH If 56 is + If 54 is + Note: 53,54,55,56 are terminals on TB204 on Power Board. SW702 and SW703 (pages 37, 38) Tach Voltage Initial Settings 3 to 4...
  • Page 66 Appendix C: Basic Set Up Sequence This section of the instruction manual is provided for those cases in which many DIP switches or potentiometer settings may have been changed and it is reasonable to assume that nothing is set correctly. In order to get the controller operating properly perform the set-up in the sequence given below.
  • Page 67 13. Adjust the output meter. (Section 5.11) 14. Check operation of Emergency Stop, if used. (Section 5.6) 15. Set up Soft Start, if used. If Soft Start is speed-actuated, perform step 18 first. (Section 5.18) 16. Check operation of Sample & Hold. (Section 5.17) 17.

  • Page 68: Electrical Connections

    Appendix 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 CONNECTIONS...

  • Page 69: Electrical Connections Of Options

    Appendix E: Electrical 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 ELECTRICAL CONNECTIONS...
  • Page 70 Appendix F: Transducer Electrical Connections Figure 45 - MODELS C, RS, & UPB TRANSDUCER WIRING...
  • Page 71 Figure 46 - MODEL RFA & VNW TRANSDUCER WIRING...
  • Page 72 Figure 47 - MODELS TR & NWI TRANSDUCER WIRING...
  • Page 73 Figure 48 - MODEL LT TRANSDUCER WIRING...
  • Page 74 Appendix G: Typical Tensions for Various Materials TYPICAL TENSIONS FOR WEB MATERIALS ACETATE 0.5 lb. per mil per inch of width FOIL Aluminum 0.5 lb. per mil per inch of width Copper 0.5 lb. " CELLOPHANE 0.75 lb. per mil per inch of width NYLON 0.25 lb.
  • Page 75 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 NOTE: Avoiding pre-loading is very important for the "C" and "UPB" type transducers. 3. Verify the electrical connections to the SteadyWeb controller. Refer to Appendices D and E. Also Section 2 or 3.
  • Page 77 TERMS AND CONDITIONS OF SALE AND SHIPMENT 1. THE COMPANY 5/1/00 Each shipment shall be considered a separate and independent Dover Flexo Electronics, Inc. is hereinafter referred to as the Company. transaction and payment therefore shall be made accordingly. If the work covered by the purchase order is delayed by the Buyer, upon demand by 2.
  • Page 78 INDEX 0-10 Volt Isolated Compensated replacements ......52 Output ......1, 2, 3, 23 Output, 0-10 Volt Nonisolated Compensated 24 volt .
  • Page 79 INDEX continued..TLS Card installed? ..... . 34 Tachometer Card installed? ....34 Taper Adjustment, front panel .
  • Page 80 217 PICKERING ROAD ROCHESTER, NEW HAMPSHIRE 03867-4630 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 ELECTRONICS, INC. DOC 801-0783 ALL RIGHTS RESERVED PRINTED IN USA...

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