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DFE WebHandler 3 Instruction Manual

Digital tension controller
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DOVER FLEXO ELECTRONICS, INC.
ISO 9001 CERTIFIED
INSTRUCTION MANUAL
™
WEBHANDLER 3
Digital
Tension Controller
DOC 801-1667
5 YEAR WARRANTY

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  • Page 1 DOVER FLEXO ELECTRONICS, INC. ISO 9001 CERTIFIED INSTRUCTION MANUAL ™ WEBHANDLER 3 Digital Tension Controller DOC 801-1667 5 YEAR WARRANTY...
  • Page 2 SALES - Product Information, Systems Application Questions, and placing orders for standard 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 Flexo Electronics, Inc.
  • Page 3 READ THIS! ™ Your WebHandler Model 3 Digital 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 3 - Calibration and Set-Up The other sections are for reference and for instruction if you wish to change the configuration at some later time.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION ONE PRODUCT DESCRIPTION PAGE 1.1 General Description ........1.2 Outputs, Version of Controller .
  • Page 6 LIST OF ILLUSTRATIONS FIGURE: 1. Front Panel and Operator Devices ......2. Examples of Tension Zones ....... . . 3.

  • Page 7: General Description

    PRODUCT DESCRIPTION SECTION 1 1.1 GENERAL DESCRIPTION ™ The WebHandler Model 3 digital tension controller automatically maintains tension of any continuous material at the value selected by the machine operator. Basic functions are divided into three parts: The first part is the tension amplifier, which supports all Dover Flexo Electronics tension transducers. (The transducers measure the actual tension in the web).

  • Page 8: Outputs, Version Of Controller

    TENSION ZONES Tension zones are created by driven or braked nip rolls, drag bars, braked or driven unwind or rewind shafts, or anything else that can increase or decrease web tension. One of these elements is at each end of every tension zone.

  • Page 9: Webhandler3

    ™ 1.3 WebHandler3 EXPLODED VIEW ™ Figure 3 - WebHandler Model 3 EXPLODED VIEW...

  • Page 10: Specifications

    1.4 SPECIFICATIONS (separated into Versions V, D, C or P where applicable) Power Input: Versions P, D, C: ......115/230 Volts 60/50Hz single phase @ 1 Amp Version V: .

  • Page 11: Standard Features

    1.5 STANDARD FEATURES SOME OF THESE FUNCTIONS REQUIRE CONFIGURING OR EXTERNAL WIRING. REFER TO SECTION 2.5 FOR WIRING AND SECTION 3 FOR CONFIGURATION. • . Disables access to certain menu functions. ANTI-TAMPER SWITCH (Keypad Lockout) • AUTOMATIC CONTROL MODE . The controller output is determined by the difference between web tension and the AUTO set point value.

  • Page 12: Options

    Analog Tension Meter in Enclosure • Ultrasonic roll diameter sensor (#149-0002). Compact user-adjustable sensor with a 0 to 10V output proportional to target distance. DFE also offers a wide variety of interconnect cables. Please consult your applications engineer for more information.

  • Page 13: Dimensions

    SECTION 2 INSTALLATION 2.1 DIMENSIONS, inches (mm) Figure 4 - CONTROLLER ENCLOSURE Figure 5 - PNEUMATICS ENCLOSURE FOR VERSION P...

  • Page 14: Selection Of Mounting Location

    2.2 SELECTING A LOCATION AND INSTALLING THE CONTROLLER A. Location for Controller: Select a location on the machine frame or a wall that will be convenient for the 1. Versions P, V, C and D: 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.

  • Page 15: Transducer Excitation

    Slide switch SW201 to select 115 volts or 230 volts. Also verify that the correct fuses are used for the voltage you have selected. 115V uses (2) 0.25 Amp (#108-0046). 230V uses (2) 0.125 Amp (108-0045) See Figure 7, below. CAUTION! The wrong selection will damage the controller! Figure 7 - POWER VOLTAGE SELECTION SWITCH 2.4 TRANSDUCER EXCITATION VOLTAGE SELECTION...

  • Page 16: Electrical Connections For Power Board, Standard And Options

    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 OPTIONS...

  • Page 17: Electrical Connections For Standard Features

    2.5.2 ELECTRICAL CONNECTIONS FOR STANDARD FEATURES 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. Figure 11 - ELECTRICAL CONNECTIONS FOR STANDARD FEATURES...

  • Page 18: Electrical Connections For Options And Accessories

    2.5.3 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 ACCESSORIES...

  • Page 19: Initial Power-Up And Overview Of User Interface

    SECTION 3 CALIBRATION and SET-UP 3.1 INITIAL POWER-UP AND OVERVIEW OF USER INTERFACE Turn unit by moving switch at bottom of unit to the position. The green Power LED will come on and after a few seconds the default display shown below will appear. Figure 13 - DEFAULT DISPLAY ™...

  • Page 20: Tension Calibration

    B. THE KEYPAD TEN ON/OFF key is used to turn output ON and OFF. When Tension is OFF, no output is produced regardless of other operating modes you are in. When Tension is ON, the controller produces output depending on whether it is in MANUAL or AUTO mode. AUTO/MAN key is used to select between the two main operating modes.

  • Page 21: Line Speed Calibration And Setup

    Figure 15 - WEB PATH FOR CALIBRATION B. USING A REMOTE TENSION AMPLIFIER (RTA) SUCH AS THE DFE FIREGUARD INDICATOR. 1. Press both ! and " keys simultaneously to enter function group menus. Select the Set-up Menu and External press .
  • Page 22 B. DC TACHOMETER OPTION CARD CALIBRATION AND SETUP The DC Tachometer card is only used when your machine has DC tachometers to measure speed. Figure 16 - DC TACHOMETER OPTION CARD Verify that a DC tachometer card is installed in the option card slot J102 on the Terminal Board, located in the back of the WebHandler3.
  • Page 23 Figure 18 - DC TACHOMETER CARD SWITCH SETTINGS AND ADJUSTMENTS 1. Initial Switch Settings 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 machine! INITIAL SW702 and SW703 SWITCH SETTINGS 1 - Open 2 - Open...
  • Page 24 C. PULSE TACHOMETER OPTION CARD CONNECTION AND CALIBRATION The Pulse Tach card is only used when your machine has pulse tachometers or encoders to measure speed. Figure 19 - PULSE TACHOMETER CARD Verify that a pulse tachometer card is installed in the option card slot J102 on the Terminal Board located in the base of the WebHandler.
  • Page 25 Figure 21 - PULSE TACHOMETER CARD SWITCHES AND ADJUSTMENTS 1. Initial Switch Settings 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 2 - Open 3 - Open...

  • Page 26: Roll Diameter Calibration And Set-Up

    5. Set the LTACH span pot. Run the machine at maximum speed. (As an alternate method, run the machine at 50% of maximum speed. Set the output voltages at 50% of the values specified below) 6. Measure the LTACH output voltage at test points TP601 (+) and TP603(-). Adjust the LTACH Span pot.
  • Page 27 Set the SW701 switches to accommodate the tachometer polarity according to the following chart: SW701 SWITCHES TB102 terminals Rtach ----- if pos 6 is + Open Closed if pos 4 is + Closed Open Set the SW703 ( RTACH ) switches to accommodate the maximum RTACH voltage measured above, using the chart below.
  • Page 28 Now you will set your RTACH Span potentiometer. Connect your red and black voltmeter leads to tach card test points TP602 (+) and TP603(-) With the machine running at maximum speed, adjust the RTACH Span potentiometer for exactly 10V at core diameter. If you already have some material on your core, measure the roll diameter and adjust the RTACH Span pot to produce a test point voltage of...

  • Page 29: Basic Set-Up Of Controller

    SET-UP OF STANDARD SECTION 4 and OPTIONAL FEATURES 4.1 BASIC SETUP OF CONTROLLER including STANDARD FEATURES ™ Your WebHandler Model 3 digital controller has been properly configured at the factory. It should not be necessary to make any changes except tension calibration and operation tuning. Use this section to verify the configuration, or to reconfigure the controller if your application requirements change.
  • Page 30 If you wish to have the ESTOP condition disable output (turn Tension Off), navigate to Setup Menus- >Tens Off By EStop, and select 2. RS232 and RS485 Serial Interfaces The WebHandler has a serial data port which can be used for two purposes. The first, is to provide connectivity to a Windows PC or notebook computer running PCWebLink software, which is supplied with each unit on a diskette.
  • Page 31 (a) Turn all power off and disconnect any cables (b) On the Control board, remove U12 (MAX233) and store for later re-use. (c) Install MAX491 (DFE P/N 104-0042) in socket U13. You will then need to connect your WebHandler to your existing computer. Again, you will...
  • Page 32 (c) Once you have successfully selected an available COM port, the PCWebLink screen will come up, with a white box with the DFE logo in it. Go to the menu bar, select File -> New. A Status box will appear.
  • Page 33 2 - If you are not connected correctly, after from 5 to 45 seconds, the program realizes that you don't have a WebHandler connected and gives you the error message, "COMMUNICATION ERROR: Please Check Cable Connection OR Heartbeat LED and restart WH3 and PCWebLink.
  • Page 34 Serial Network ID, Remote auto/manual switch, and manual and auto setpoint sources. Diagnostic (to be used only with assistance of DFE technical service personnel): Reading raw A to D converter values, selecting and writing to the D to A converters, reading port pin values,...
  • Page 35 Figure 30 - DIAGNOSTIC SCREENS Figure 31 - TUNING and DATA TRANSFER SCREENS Tuning: (see below) Data Transfer: ALWAYS use this screen to save your setup changes before exiting the program. Changes not STORED to DEFAULT SETUP will not affect the unit after a power OFF/ON cycle. Be aware the unit always powers up in the DEFAULT SETUP configuration.(see also (5) below) To store a setup in your WebHandler: Select DEFAULT SETUP in the Store Setup As pulldown box.
  • Page 36 This provides the ability to store known good setups outside the controller for archival purposes or perhaps for DFE technical service to evaluate a setup if a controller is not operating correctly. It also provides a means to quickly configure multiple controllers for similar applications, and for other uses.
  • Page 37 Speed and Roll Diameter and allows the user to turn Tension On or Off, and select Manual or Auto Control Mode to facilitate the process. Standard tuning instructions still apply (see Section 4.4). Remember to STORE your settings when finished. Using the Host Interface: ™...
  • Page 38 3. Soft Start Soft start is normally used only in braked UNWIND zone applications. Turn off soft start when the controller is being used to control rewind or intermediate tension because it serves no purpose and it may not be possible to leave soft start. Soft start can be actuated in one of three ways; 1. by sensing a loss of tension, 2.
  • Page 39 SS Output Level (4) Navigate to and adust to the output you want while in Soft Start. The range is 0 to 100% of maximum output. It is best to set it low, but high enough to produce enough tension to exceed the trip point tension or the controller may not be able to get out of Soft Start.
  • Page 40 6. Setup for Tension Limit Switch The TLS feature is typically used to provide an alarm when web tension exceeds or drops below user determined levels. It can also be configured to provide an alarm when tension is within a specified operating range.
  • Page 41 Set TLS Delay A delay can be entered in the function . Typically a delay of no more than 3 seconds is adequate to prevent false triggering. If you wish to have either TLS Hi or TLS Lo turn tension Off, Tens Off ByLo TensOffByHi navigate to Setup Menus->...

  • Page 42: Setup Of Optional Features

    For an external Manual/Auto switch input connect one side to TB101-21 (Gnd) and the other to one of the unused digital inputs (TB101 pin 3 or TB101 pin 5). This should be a maintained type switch. Figure 36 - CONNECTIONS FOR REMOTE AUTO/MANUAL SET-POINT POTENTIOMETERS AND MANUAL/AUTO SWITCH For a Manual potentiometer input, navigate to ManSetptSrc and select either Line Spd Input (pin 8), Roll Spd Input (pin 10), RTA input (pin 7), or Diameter input (pin 12).

  • Page 43: Special Set-Up Notes

    C. TAPER TENSION (TTF Option ) Taper tension is a feature which automatically reduces the tension set-point, and hence the tension, in a roll as the diameter increases. Taper tension is usually needed when winding rolls with large build-up ratios, or when winding slippery materials, so that the roll does not crush the core yet the material does not telescope.
  • Page 44 1. To change input and output voltages, set the SW1 switch on the V-Out Board as follows: Figure 39 - HIGH VOLTAGE OUTPUT SWITCH SETTINGS SPAN OFFSET pots (RT1 and RT2 on V-Out board) are set at the factory and should not require any adjustment.
  • Page 45 Figure 41 - NON-STANDARD SERVO VALVE DRIVER CARD (top view) 1. Make sure the shop air provided to the servo valve is clean and dry and that the input air pressure is regulated such that the output pressure is no more than 75 psi. For more reliable operation, install an in- line air filter to keep out dirt, oil and moisture.

  • Page 46: Tuning Adjustments

    5. For 0 to 10V ONLY Adjust RT1 (SPAN) on the Control board fully clockwise. Refer to pneumatic valve manufacturers instructions for calibration. 6. For 4 to 20mA Refer to pneumatic valve manufacturers instructions for calibration. 7. Check servo valve for proper operation. Connect a pressure gauge to the valve output. Set the external air pressure regulator to 80psi (5.5 bar).
  • Page 47 4. Accelerate and decelerate the machine while watching the tension display. If tension oscillates, readjust (increase) Stability or (reduce) Gain. If Tension lags excessively (reduce) Stability or (increase) Gain. Try changing the Stability first, If Stability will not hold steady tension, use Gain 5.

  • Page 48: Basic Operation

    Again, if this is caused by a wiring error, disconnecting the output wiring at Tb101-17 and -19 (for non-isolated D versions) will eliminate the error condition. Otherwise the problem is likely within the controller, which should be returned to DFE for service.

  • Page 49: Operation Of Additional Functions

    5.2 OPERATION OF ADDITIONAL FUNCTIONS The unit is factory configured for your application. If additional changes become necessary, your unit may be programmed by adjusting settings contained in various functions. Functions are arranged into four menu groups: Operator, Calibration, Set-up, and Diagnostic. These are shown in the menu group chart in Appendix D. To access the main menu, first press and hold the ! ! ! ! and "...
  • Page 50 G. CHANGING UNITS OF TENSION MEASUREMENT Your controller comes factory configured with requested units for your tension measurement application. You may later find that other units are more appropriate, e. g. metric units, or units which take into account Tension web width.
  • Page 51 Start can be Triggered by Low Tension, Low line speed or an External Contact Closure, or any combination of these. All Soft Start functions are set from within the Setup Menu. The set-points for Tension and Speed to trigger soft start are adjustable, as is the Output level. The delay prior to entering soft start is also adjustable.

  • Page 52: Section Six Care And Maintenance

    SECTION 6 CARE AND MAINTENANCE It is not necessary to perform any type of maintenance on the controller. However, you may find it worthwhile to observe whether there is a buildup of dust, debris, or moisture on or near the unit after 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.

  • Page 53: Section Seven Troubleshooting Tips

    (Fax: (603) 332-3758, E-mail: techsupport@dfe.com ). We offer experienced technicians whose responsibility it is to make sure you are satisfied with your DFE equipment. They will be pleased to help. 2. The most common source of improper operation of tension equipment is incorrect installation of the tension transducers or using transducers of the wrong load rating.

  • Page 54: Standard Circuit Boards

    SECTION 8 REPLACEMENT PARTS LIST 8.1 STANDARD CIRCUIT BOARDS Power Board 723-1324 Control Board 723-2020 Terminal Board 723-2022 8.2 OPTIONAL CIRCUIT CARDS DC Tach Option Card 723-0101 Pneumatic Enclosure Assembly 723-2037 (Version P) Isolated Output Card 723-1439 (Version D) Non-Standard Servo Valve Driver Card 723-1409 (Version C) V-Out Board 723-1346 (Version V)

  • Page 55: A Circuit Boards

    Appendix A: Circuit Boards Figure 45 - CONTROL BOARD Figure 46 - POWER BOARD (top view)
  • Page 56 Figure 47 - TERMINAL BOARD Figure 48 - V-OUT BOARD (top view)
  • Page 57 Figure 49 - NON-STANDARD SERVO VALVE DRIVER CARD Figure 50 - ISOLATED OUTPUT CARD...
  • Page 58 Figure 51 - DC TACH OPTION CARD Figure 52 - PULSE TACH OPTION CARD...

  • Page 59: B Dip Switch Settings & Jumpers

    Appendix B DIP Switch Settings & Jumpers DC TACH CARD INITIAL SW702 and SW703 SWITCH SETTINGS SW701 SWITCHES Ltach ----- if pos 1 is + if pos 3 is + Rtach ----- if pos 6 is + if pos 4 is + (NA = Not Applicable SW702 and SW703 SWITCHES Volts DC...

  • Page 60: C Basic Set-Up Sequence

    Their locations are stated after the setup step descriptions. WARNING: This procedure will also clear any factory settings done by DFE to configure your controller. This procedure has no provision to undo the results. There is no warning or verification in the controller. We recommend that you call Technical Support at DFE prior to using this procedure.

  • Page 61: D Functions Menu Chart

    Appendix D: Function Menus Chart...

  • Page 62: E Description Of Functions

    Appendix E: Description of Functions OPERATOR MENUS Display Select Set Manual Setpt Allows the user to select what value appears on the second line Allows the user to specify how much output the controller will of the Default Display. produce when it is in Manual mode. List of choices: Set point Range of values:...
  • Page 63 CALIBRATION MENUS Set Zero Tension Tension Range This function allows the user to establish a new zero point for This function allows the user to set or change the maximum tension measurement. This may become necessary if the expected full scale tension value for the application. Setting a transducers were not allowed to warm up long enough before tension range is required for initial calibration of the controller.
  • Page 64 Diameter information is required when the controller is operated in SFDiaCompTenTrm mode, or when the Taper feature is because doing otherwise would introduce an unwanted used. transient into the system. Consult DFE Technical Service before changing the setting of this function. List of choices: Direct List of choices: 0.0, 0.5, 1.0, 1.5, 2.0, 2.5, 3.0,...
  • Page 65 SETUP MENUS continued. . . TensnSoftStart SwitchSoftStart Enabling this feature causes controller output to be at the level Enabling this function causes controller output to be at the level set in the SS Output Level function, when the tension drops set in the SS Output Level function, when the Soft Start below the level set in the SS Tension Trip Pt function, for the contacts are closed.
  • Page 66 SETUP MENUS continued. . Pos Output Limit Neg Output Limit Some applications work best when the maximum output is Some applications work best when the minimum output is limited to some value less than the maximum possible value. limited to some value less than the minimum possible value. This function allows the user to set that value, as a percent of This function allows the user to set that value, as a percent of maximum.
  • Page 67 These Diagnostic functions are intended as a troubleshooting aid when working closely with DFE Technical Support personnel. Do not attempt to modify these settings without consulting DFE Technical Support first, or settings may be lost, or unpredictable results may occur!!
  • Page 68 DAC. This value is preset at the factory during final unit Do not use this function unless instructed to do so by DFE Test and Setup for your order. Do not use this function unless...

  • Page 69: F Host Interface Commands And Responses

    DIAGNOSTIC MENUS continued. . Zero Select ADC Span Select ADC Electronically calibrates the “zero” of the ADC you Electronically calibrates the “span” of the ADC you already selected in the Select ADC menu. already selected in the Select ADC menu. This menu should be used only after you have already set your (Note: Before using this menu, go to the Read ADC Zero value using the Zero Select ADC menu.
  • Page 70 Appendix F: Host Interface Commands & Responses 1. HOST/WEBHANDLER COMMANDS AND RESPONSES $#a(+4) Set Auto setpoint Host sets automatic set-point to be equal to the value contained in the following four bytes, where the data format is: “X.XX” when the full scale Range setting is between 1.00 and 9.99 “XX.X”...
  • Page 71 HOST/WEBHANDLER COMMANDS AND RESPONSES continued... $#K(+1) Store default setup Store the default setup in WebHandler memory locations 1 through 9, as selected according to the last byte (e. g. $1K6 will store the default setup in memory location 6). WebHandler response: (Command receipt acknowledged;...
  • Page 72 HOST/WEBHANDLER COMMANDS AND RESPONSES continued... Inquire tension value Host inquires what the present tension value is. WebHandler response: %#t(+4) Tension value is contained in the following four bytes, where the data format is: “X.XX” when the full scale Range setting is between 1.00 and 9.99 “XX.X”...

  • Page 73: G Pcweblink Screens

    Appendix G: PCWebLink Screens Figure 53 - PCWebLink RUN SCREEN Figure 54 - PCWebLink CONFIG 1 AND CONFIG2 SCREENS...
  • Page 74 Figure 55 - PCWebLink TLS AND SOFT START SCREENS Figure 56 - PCWebLink CALIBRATION AND MISCELLANEOUS SCREENS...
  • Page 75 Figure 57 - PCWebLink DIAGNOSTIC SCREENS Figure 58 - PCWebLink TUNING AND DATA TRANSFER SCREENS...

  • Page 76: H Transducer Electrical Connections

    Appendix H: Transducer Electrical Connections Figure 59 - MODELS C, RS, & UPB TRANSDUCER WIRING...
  • Page 77 Figure 60 - MODEL RFA & VNW TRANSDUCER WIRING...
  • Page 78 Figure 61 - MODELS TR & NWI TRANSDUCER WIRING...

  • Page 79: I Typical Tensions

    Figure 62 - MODEL LT TRANSDUCER WIRING...
  • Page 80 Appendix I: Typical Tension 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 81: Terms And Conditions

    TERMS AND CONDITIONS OF SALE AND SHIPMENT 1. THE COMPANY payments shall be made on the purchase price based upon percentage of completion. Dover Flexo Electronics, Inc. is hereinafter referred to as the Company. 7. TAXES 2. CONFLICTING OR MODIFYING TERMS Any tax, duty, custom, fee or any other charge of any nature whatsoever imposed by any governmental authority on or measured No modification of, additions to or conflicting provisions to these...
  • Page 82 NOTES...
  • Page 83 INDEX 0-10 Volt Control Output ....2, 10, 11, 36, 38 PCWebLink Software calibrated ........15 Set-up .
  • Page 84 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 © 2006 DOVER FLEXO ELECTRONICS, INC. DOC 801-1667 ALL RIGHTS RESERVED DFE 05-08 -2006 PRINTED IN USA...

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