AUTOK TC818 Instruction Manual
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AUTOK TC818 Instruction Manual

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TC818
TENSION CONTROLLER
INSTRUCTION MANUAL(V4.00)

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Summary of Contents for AUTOK TC818

  • Page 1 TC818 TENSION CONTROLLER INSTRUCTION MANUAL(V4.00)

  • Page 2: Table Of Contents

    Table of Contents 1 Introduction ................1 1.1 Overview ................1 1.2 Features ................1 1.3 Order code ............... 2 1.4 User interface ..............2 2 Mounting and electrical wiring ..........4 2.1 Dimension ................ 4 2.2 Mounting ................4 2.3 Electrical connection ............

  • Page 3: Introduction

    1 Introduction 1.1 Overview The TC818 tension controller is part of a closed-loop tension control system with tension sensor feedback. The controller continuously controls the web tension to the setting tension value and display the true web tension on an LCD screen. The screen will display the tension applied to each tension sensor separately.

  • Page 4: Order Code

    36V/3A main output which can drive magnetic powder brake/clutch, software version V3.00. (2) TC818-24V/V05/V05/0-V4.00 designates the controller with 24V/4A main output and with 0~ 5V auxiliary output 1 and auxiliary output 2, drive torque motor driver or inverter, software version is V4.00.
  • Page 5 Tension Controller TC818 1. Set/Esc Set: Enter the next menu screen or confirm operation. Esc: Back to previous menu screen or “Confirm/Exit” after finishing the setting of the value. 2. AUTO/MAN switch and indicators The automatic mode and manual mode can be switched by pressing this key.

  • Page 6: Mounting And Electrical Wiring

    Tension Controller TC818 2 Mounting and electrical wiring 2.1 Dimensions kg/N TC818 Tension Controller LOCK OUTA OUTB AUTO MANUAL AUTO OUTPUT ON/OFF AUTOK 16.5 unit: mm 2.2 Mounting The controller can be installed on floor, wall or panel. 4-M4*12 Mounting screw...

  • Page 7: Electrical Connection

    Tension Controller TC818 2.3 Electrical connection 2.3.1 Connection notes [1] In order to avoid electrical noise to the input signal, the signal line should be away from the power line. [2] If the AC power supply is connected to the I/O terminals or DC supply terminals, the tension controller will be burn out.
  • Page 8 Tension Controller TC818 2.3.3 Terminals description Terminal block 1: Terminal Specification Comments PSL, PSN 85~264V AC, 50/60 Hz Controller Power supply ZT, ZTC Relay, 3A/250VAC, NO Tension alarm output PA NA 24V/4A or 36V/3A drive Reel A magnetic powder clutch/brake...

  • Page 9: Menu Operation

    Tension Controller TC818 3 Menu operation 3.1 Overview of operation Power ON After powered on, the controller will return to the state before T C 8 1 8张 力 控 制 器 shutting down. 软 件 版 本: ver2.20 Auto Monitor...

  • Page 10: Introduction To Major Screens

    Tension Controller TC818 3.2 Introduction to major screens (1) Automatic tension control: constant tension Measured tension Auto Monitor PV.: 24.9kg Alter the setting tension using the Inc/Dec key or digital knob SV.: 25.0kg Out: 39.5 % Output (2) Automatic tension control: taper tension...

  • Page 11: Parameter List

    Tension Controller TC818 3.3 Parameter list The table below divided the parameters into several categories by the functions. Parameter Adjustable Range Default Description Function Setting: The essential parameters, set prior Auto control Function Auto control Automatic tension control and radius tension control...
  • Page 12 Tension Controller TC818 (Continued) Parameter Adjustable Range Default Description Limit of Setting Value Max SetVal 0.0~999.9kg 50.0kg The maximum setting value (upper limit) Min SetVal 0.0~999.9kg 0.0kg The minimum setting value (lower limit) Start/Stop: The outputs and timing in start/stop process (see 4.2.3 Run and stop operation...

  • Page 13: Automatic Tension Control

    Tension Controller TC818 4 Automatic tension control Please debug by stepping through the following steps: [1] Assure that the mounting and connection of the tension controller is completed and correct, and switch on the power. [2] Assure that the mounting and connection of the tension sensor is correct, check the output signal of the tension sensor.
  • Page 14 Tension Controller TC818 4.1.2 Setting of measurement related parameters In order to get the precise measurement of the web tension, the measurement related parameters must be set properly: 1. Sensor[24] The controller can be used with one or two tension sensors, please make the selection according to the number of the mounted sensors.
  • Page 15 Tension Controller TC818 4.1.3 Calibrate tension In order to implement the closed loop tension control system, the tension controller must be calibrated after installation, and only the proper calibrated controller can get the desirous measurement precision. The controller uses two-points linear calibration method, the process is very easy.
  • Page 16 Tension Controller TC818 4.1.3.3 Span Calibration Suspend weight W kg Note: The weight must be equal to or greater than the ½ full-scale of the tension sensor’s measurement range. Highest position Tension Sensor (calibrate 100) weight Pivot point sensor Lowest position...

  • Page 17: Operation

    Tension Controller TC818 4.2 Operation After finishing the tension calibration and the measured tension is right, the controller can be tested with manual operation and automatic operation. First use manual operation, if the tension system works well(get the stable tension), the controller can be switched to automatic mode to perform closed loop tension control.
  • Page 18 Tension Controller TC818 4.2.3 Run and stop operation 4.2.3.1 Run/Stop switch S1 ON NPN Pulses S1 OFF Stop S1: Run/Stop switch tension sensing roller pulses input The start and stop operation is controlled by the Start/Stop Switch(S1) connected to MC1 and MCC.
  • Page 19 Tension Controller TC818 4.2.4 Reel exchange In the two-reel operation tension systems, the reel exchange is controlled by the Reel exchange switch. This function is applicable when material on reel is over or full. Plating roller Tension Plating solution sensor...
  • Page 20 Tension Controller TC818 Reel Exchange Switch Switch OFF: Reel A will be active; Switch ON: Reel B will be active. Reel A Reel A Reel B Reel B Exch. Time[14] Reel A Output Aux. Time[15] Exch. Output[13] Time Exch. Time[14] Reel B Output Aux.
  • Page 21 Tension Controller TC818 4.2.5 Acceleration and Deceleration Acceleration The acceleration operation is controlled by the Accel. button which is connected between MC3 and MCC. Once the Accel. button is pressed, the output before pressing the button times Inc Coeff.[16] will be the control output, this speeds up the system.
  • Page 22 Tension Controller TC818 4.2.6 Setting of PI In automatic mode, the stability and control precision of the tension system is affected by proportional band, integral time and dead band, if the system is not stable, alter the value of the P rop.
  • Page 23 Tension Controller TC818 4.2.7 Output limit 20.Max output 21.Min output HPL= 100.0 % LPL= 0.0 % Esc:Confirm/Exit Esc:Confirm/Exit The parameters Max output[20] and Min output[21] limits the maximum (upper limit) and minimum (lower limit) value of the output. According to the specific devices, set the proper value for these parameters.
  • Page 24 Tension Controller TC818 43.OUT2 Mode Sync Output Output B PV Transmit The function of Main Output B and Aux. Output 2 can be configured with OUT2 Sync Output, the signal on Reel A and Reel B will be the same.

  • Page 25: Taper Tension Control

    Tension Controller TC818 4.3 Taper tension control 4.3.1 Introduction In winding systems, decreasing the tension while the winder radius increases is called taper tension control, this can make the inner of the winder tighten and the outer of the winder loosen, thus avoid slipping.

  • Page 26: Diameter Tension Control

    Diameter tension control: Unwinding TC818 tension controller The TC818 continuously monitors the pulses on the main roller and material tube, then use these data to calculate the radius of the material tube. Using the tube radius, setting value, rated torque[39] of the powder brake and the built-in algorithm, the controller regulates the output to accomplish the control of the web tension.

  • Page 27: Roll Radius Monitoring

    Tension Controller TC818 5.2 Roll radius monitoring 5.2.1 Proximity switch and encoder connections Main roller pulse* Reel A pulse* Reel B pulse* NPN pulse 5.2.2 Methods of measurement 32.Rad Detection There are two methods available for monitoring the roll radius: Thick Sum and Ratio.
  • Page 28 Tension Controller TC818 5.2.2.2 Ratio Radius R0[35] Pulse N1[36]/r R(current radius) Proximity switch/Encoder Pulse N2[37]/r Proximity switch/Encoder When using this monitoring method, the controller counts the pulses generated by the proximity switches which mounted on the material roll and main roll(i.e. the...

  • Page 29: Basic Operations

    Tension Controller TC818 5.3 Basic operations 5.3.1 Run/Stop control The run and stop operation is controlled by the Start/Stop Switch(S1) S1 ON connected to MC1 and MCC. For details of run/stop operation, please refer to “4.2.3 Run and Stop”. S1 OFF...

  • Page 30: Constant Tension Control

    Tension Controller TC818 5.4 Constant tension control 5.4.1 Automatic mode RadiTension Rad: 350mm Measured radius SV.: 25.0kg Alter the setting tension using the Inc/Dec key or digital knob Out: 28.5 % Output 5.4.2 Manual mode Man Monitor Measured radius Rad: 350mm SV.:...

  • Page 31: Taper Tension Control

    Tension Controller TC818 5.5 Taper tension control The taper tension control function can also be accomplished in radius tension control systems. The greater value for Taper t1[31], the greater change of the tension while increasing of the reel radius. If the Taper t1[31] equals to 0, the controller will perform the constant tension control.

  • Page 32: Program Tension Control

    Tension Controller TC818 5.6 Program tension control The program tension control is a special application Output(%) of the diameter tension control. According to the pre- set programs and the change of roll diameter, the OUT6 controller increases/decreases the output power to achieve tension control purpose.
  • Page 33 Tension Controller TC818 5.6.3 Introduction to program parameters Each program consists of six points, each point is a radius-output pair. The TC818 tension controller can store 10 programs in its non-volatile memory. 5.6.3.1 Program number 54.NO. When need to perform the program tension control for several kinds of Pr.n...

  • Page 34: Additional Functions

    Tension Controller TC818 6 Additional functions 6.1 Language 50.English/ 中文 The controller has two built-in language: Chinese and English, 中文 to change the language: (1) Scroll to English 中文 [50] and press Set to enter English (2) Select the language (3) Press Esc to confirm &...

  • Page 35: Serial Communications

    Tension Controller TC818 7 Serial communications 7.1 Overview Digital Communication allows the controller to communicate with a PC or a networked computer system. The RS232 standard allows a single instrument to be connected to a PC, a Programmable Logic Controller, or a similar devices using a cable length of less than 15m.
  • Page 36 Tension Controller TC818 7.5 Reading Data from the Instrument To read data, a 'poll' message is issued to the instrument. This message takes the following format: [EOT](ADR_H)(ADR_H)(ADR_L)(ADR_L)(C1)(C2)[ENQ] Each item in the above description represents a single ASCII character. The items in bold type and square brackets are control characters used to frame the message, whose values may be determined by reference to the table on the previous page.
  • Page 37 Tension Controller TC818 7.6 Writing Data to the Instrument To write data, a 'select' message is issued to the instrument. This message takes the following format: [EOT](ADR_H)(ADR_H)(ADR_L)(ADR_L)[STX](C1) (C2)<DATA>[ETX](BCC) Each item in the above description represents a single ASCII character. The items in bold type and square brackets are control characters used to frame the message, whose values may be determined by reference to the table on Page 1.
  • Page 38 Tension Controller TC818 7.7 Communication Parameters List Order ASCII/HEX Parameter Adjustable Range 50 56 Process Value (Read only) 4F 50 Output (Read only) 0~100.0% 53 50 Current target tension Read only 53 4C Setting value SPH SPL 52 58 Measured Radius...

  • Page 39: Appendices

    Tension Controller TC818 8 Appendices 8.1 Parameters screen 01.Init Radius 02.Thickness 03.Start Freq. 04.Alarm Value 05.Prop. Band 50mm Thick= 0.020mm 01Hz AL1= 0.0kg PROP= 200.0kg Esc Confirm/Exit Esc:Confirm/Exit Esc:Confirm/Exit Esc:Confirm/Exit Esc:Confirm/Exit 06.Inte. Time 07.Dead Band 08.Start Output 09.START Gain 10.Start Time INTT= 1.0S...

  • Page 40: Troubleshooting

    Tension Controller TC818 8.2 Troubleshooting Appearance of failure Possible malfunction Solution The power supply is 110-264 VAC. The controller does not work Power fails or fuse fused. 1. Check the connection of power supply. after powered on 2. Replace new fuse(4A).

  • Page 41: Technical Specifications

    Tension Controller TC818 8.3 Technical specifications 1. Micro-displacement based tension sensor(signal range: 200mV, power supply: 5VDC) Tension Inputs 2. Strain gauge based tension sensor(signal range: 20mV, power supply: 10VDC) 3. 2K Potentiometer Proximity switch or encoder, NPN signal, maximum frequency 15KHz...
  • Page 42 SHENZHEN AUTOK ELECTRONICS CO.,LTD 518054 0755 86127893 8 6127395 13534077321 0755 86127395 Http //www.china-autok.com E-mail dly.autok@163.com...

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