INSTALLATION AND OPERATING INSTRUCTIONS - Montalvo … · The Montalvo X-3000ce-UW PID analog cont...

Version 2.0 Pub. date: 1/3/02 v11PID Web Tension Controller

INSTALLATION AND OPERATING INSTRUCTIONS

X-3000ce-UW

Table of Contents

1 General Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

2 Technical Data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82.1 X-3000ce-UW Electrical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

2.2 X-3000ce-UW Mechanical - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

3 lnstallation and Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - 113.1 Mechanical Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

3.2 Electrical Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14

3.3 Quick Setup Guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - 153.4 Startup and Adjustment. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

3.5 Basic Diagrams for Standard Application - - - - - - - - - - - - - - - - - - - - 22

3.6 Complete Wiring Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24

3.7 Terminal Blocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

3.8 Basic Wiring Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

3.9 Digital Input: Standard Functions - - - - - - - - - - - - - - - - - - - - - - - - - - 30

3.10 Analog Signals: Standard Functions - - - - - - - - - - - - - - - - - - - 46

3.11 Input and Output: Special Functions - - - - - - - - - - - - - - - - - - - - - - 47

3.12 Web Break - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48

3.13 Range Expander of X-3000-ce-UW - - - - - - - - - - - - - - - - - - - - - - - 50

3.14 Diameter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

3.15 Operation of the Controller Menu - - - - - - - - - - - - - - - - - - - - - - - - - 59

3.16 Menu Tree Diagnostic - - - - - - - - - - - - - - - - - - - - - - - - - - 603.17 Menu Tree - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

3.18 Setup Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62

3.19 Hardware Adjustment and LEDs - - - - - - - - - - - - - - - - - - - - - - - - - 63

4 Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 644.1 Tension Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64

4.2 Regulation Parameter, Gain, Ratio, P and D - - - - - - - - - - - - - - - - - 65

4.3 Tuning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66

4.4 Customer Parameter Settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67

5 Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68

6 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70

1/3/02 3

1 General DescriptionThe Montalvo X-3000ce-UW PID analog controller provides precise automatic control of web tension. The progressive PID regulator automatically compensates for roll diameter. The X-3000ce-UW is used in a closed loop, of which the load cell roller and brake (or other tension-affecting device) are a part.

To properly set up and operate the X-3000ce-UW 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). A typical pneumatic system is displayed; however, the same principles apply to any other closed-loop control system. The control outputs of 4 to 20 mA and 0 to 10 volts DC enable the X-3000ce-UW to interface with a variety of output devices to control web tensioning brakes, clutches, and motors.

Load Cell Function

Two load cells (also called transducers) are normally used. The signals from the load cells are summed together to indicate total web tension across the entire web. Each load cell contains two strain gauges connected in a series. The two load cells are connected so that the four strain gauges form a Wheatstone bridge configuration supplied with + 2.5 VDC. The web tension transfers a force to the load cell roll, changing the resistance values in the bridge. The resulting voltage change is amplified and calibrated to display actual web tension.

Converter Function

The I/P converts the 4 to 20 mA regulator output to a proportional 0 to 75 PSI (0 to 6 bar) to control the brake. Other converters may be used, depending on the application.

Brake Function

One or more brakes may be controlled, converting the pneumatic output pressure from the I/P into torque. This torque in turn changes the web tension.

Auto Mode Function (Closed Loop)

The operator sets the desired tension with the auto setpoint potentiometer. 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-3000ce-UW can quickly compensate for speed and diameter changes, and for other factors that affect tension during the process.

1/3/02 5

1 General Description

Manual Mode Function (Open Loop)

The operator sets the desired brake pressure with the manual potentiometer. The web tension is still measured and displayed on the tension meter, but is not regulated in this mode. To maintain tension, the operator must make constant adjustments.

Load cell

I/P converter

X3000ce-UW controller

Montalvobrake

50

20 80

100%0MANUEL/ AUTO

TENSION OFF/ON

AUTOMANUEL

OUTPUT

50

20 80

100%0

Type: X3000-ce-UW SN: 3455Supplyvoltage: 115/230V 60/50HzSupplycurrent : <0.5A

PR035.dsf

Air filter

6 1/3/02

General Function and Standard Operation Cabinet Version

1. Manual setpoint 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 100% output.)

2. Auto setpoint In auto mode, the controller automatically regulates output so that actual tension reaches the tension setpoint (appears on a scale of 0 to 100% on the meter).

3. Actual tension Displays actual tension on a scale of 0 to 100%.

4. Controller output meter Displays controller/regulator output on a scale of 0 to 100%.

5. Manual / Auto switch Switches between manual and auto mode.

6. Tension on/off switch Turns tension on and off. Output is zero when off.

7. Green power LED Indicates that power is on.

IL030.dsf

OPTION:-Cal. low/high

OUTPUT

50

20 80

100%0

50

20 80

100%0

MANUAL/ AUTO

TENSION OFF/ON

AUTOMANUAL50

20 80

100%0

3 4 5 6

1 2

OPTION:-Splice level

7

1/3/02 7

2 Technical Data

2 Technical Data

2.1 X-3000ce-UW ElectricalAC Input 115 or 230 VAC +10% (IEC TC77B WG3) 48 to 62 Hz

Fuse Size (fuse not installed by factory)115 V-160 mA T (slow-blowing type) Ø5 x 20 mm230 V-80 mA T (slow-blowing type) Ø5 x 20 mm (Both types are supplied)

Overvoltage Category II (IEC 664)2 kV in 1 minimum primary to secondary

Pollution Degree 2

Material Fire Classification 94V0

Maximum Power Consumption 12 VA

Maximum Fuse Input 10A

Noise Immunity EN 50082-2 industrial

Noise Emission EN 50081-1

Load Cell Supply ±2.5 VDC ±5%

Load Cell Input 0 to ±250m VDC

Zero Range (tare) 100% of load cell rating [max. 500mVDC (+/- 250 mVDC)]

Calibration Range Gain: 11 to 480

Temperature Range 0 to 50° C (32 to 122° F) operating-10 to 80° C (14 to 176° F) storage

Degree of Protection IP 54 / IP 10 for non-cabinet version

Regulator Outputs

0 to 10 VDCMaximum load - 5 mA4 - 20 mA / 0-20 mA RL = 0 to 1000Ω

Meter Outputs

0 to 100 µARO = 100 KΩ 0 to 10 VDCMaximum load - 5 mA

Analog Input Voltage 0 to 10 VDCRI = 100KΩ

Digital Input Voltage 15 to 30 VDCRI = 10KΩ

Digital Output Voltage24 VDC ±5%±15Imax for a digital output: 100mATotal Imax for all 4 outputs: 250mA (if internal power supply is used).

Standards Designed to meet UL 508 and EN 60204

8 1/3/02

2.2 X-3000ce-UW Mechanical

2.2 X-3000ce-UW MechanicalDimensions (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" x 6.3" x 2.36")

Weight (Non-cabinet version) 1 kg (2.2 lbs.)

Cabinet version Non-cabinet version

50

20 80

100%0

MANUAL AUTO

TENSION OFF/ON

AUTOM A N U A L

OUTPUT

50

20 80

100%0

Type: X3000-ce-UW SN: 3455Supply voltage: 115/230V 60/50HzSupply current: <0.5A

IL007.dsf

IL140.dsf

1

2

3

4 5

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8

9 1

0 1

1 12

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6 1

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3 2 4

25

26

27 2

8 2

9

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9 40

41

4 2 4

3 4

4 4

5 46

47

48

49 5

0 51

52

53

54 5

5 56

57

58

R1 R2 R3 R4 R5 R6

Enter

-

+Back Space

Down

Up

DO 4DO 3DO 2DO 1

DI 8DI 7DI 6DI 5DI 4DI 3DI 2DI 1

00

XXXXXXXX 0%

PE

Type : X-XXXXce-XXVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000

230

115

L N

1/3/02 9

3 lnstallation and Setup

3 lnstallation and Setup3.1 Mechanical Installation

IL076.dsf

160 mm

160

mm

1

2

3

4 5

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8

9 1

0 1

1 12

13

14

1 5 1

6 1

7 1

8 19

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9

30 3

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9 40

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42 4

3 4

4 4

5 46

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49 5

0 51

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54 5

5 56

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58

148

mm

120 mm

55 m

m

PEL N

R1 R2 R3 R4 R5 R6

Enter

-

+Back Space

Down

Up

DO 4DO 3DO 2DO 1


00

PE

230

115 TENSION 0%

L N

Type : X-3000ce-UWVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000

10 m

m

1/3/02 11


3.1.1 Cabinet

The X-3000ce-UW controller cabinet should be mounted in a dry place, away from any source of heat. The mounting surface should be free of any excessive vibration. If possible, the controller should be mounted at eye level and in a location accessible to the operator. If used, mount the I/P converter or P-3000 as close to the brake as possible.

Enclosure with doors open

Note: Plastic latch to hold door open

18.00" (457)

8.25"(210)

10.23"(260)

11.81 (300)

12.99" (330)

6.43" (163) 0.39" (10)Space for mounting

bracket

6.82" (173)

50

20 80

100%0

MANUAL/ AUTO

TENSION OFF/ON

AUTOMANUAL

OUTPUT

50

20 80

100%0

Type: X3000-ce-UW SN: 3455Supplyvoltage: 115/230V 60/50HzSupplycurrent: <0.5A

IL009.dsf

Avoid mounting the controller cabinet close to drive controllers or any other equipment that produces large amounts of EMI.

12 1/3/02

3.1 Mechanical Installation

3.1.2 X-3000-ce-UW CabinetFigure 1 mount standard. For other mounting brackets, consult factory.

Fig. 1

18°18°

Fig. 2

20°

45°

Fig. 3 Fig. 4 IL037.dsf

Cutout dimensions: 320 x 250 mm

1/3/02 13


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.

Select the PCB fuse size according to the input voltage selected. The maximum external fuse on the input is 10 A.

Note: 0VDC and PE are internally connected.

Note: Double-check accuracy of all wiring connections before applying power to the controller. Damage caused by improper wiring is not covered under warranty.

EMC Requirements

Connect protective ground wire to terminal marked PE. Ground wires should be as short as possible. Connect PE, mounting plate, and cabinet to a common ground.

Use only shielded cable for all external connections. For analog signals, terminate shield at controller end; for digital signals, terminate shield at both ends. For cabinet versions, connect shield to the cabinet at the point where the cable enters, whether to a buss bar or to the connector housing. Keep the shield as short as possible (not to exceed 10 mm or 0.4 inches). For best results, clamp the uninsulated shield directly to the buss bar with the strain reliefs provided.

Keep signal cables away from supply cables or any wires that conduct high current. For best noise immunity, run signal cables close to the machine frame, mounting plates, or other grounded structures.

Safety InformationThe following safety symbols appear in this manual.

Caution Electrical HazardFailure to follow installation and setup instructions in this manual may result in equipment damage or personal injury.

Failure to follow wiring instructions in this manual may result in equipment damage, personal injury, or death.

14 1/3/02

3.3 Quick Setup Guide


3.3.1 Introduction

The controller system will typically include the following components:

• 1 X-3000-ce-UW• 1 I/P converter (MPC 3, 4, or 5)• 1 air filter (5 and 0.3 µm)• 2 load cells• 1 brake

Note: If the system includes other equipment, please refer to the appropriate sections of the manual.

3.3.2 Mechanical and Pneumatic Installation

1. Mechanical Installation

Mount all components on the machine.

Note: Place I/P converter close to brake so that tubing is as short as possible.

The Quick Setup Guide is intended to help get the system up and running in a short period of time.

To maximize system performance, please read the entire manual.

50

20 80

10 0%0

50

20 80

10 0%0

M A N UE L /

A U TO

T EN S IO N

O FF /O N

AU TOM A N UE L

O U TP U T

Typ e: X 300 0- ce -U W S N: 34 55

S up pl yv ol t ag e: 1 15 /2 30V 60 /5 0H z

S up pl yc urre nt : < 0. 5A

Air filter

Start and stop signal frommain cabinet

115/230 VacPower supply

Load Cell 1 Load Cell 2

Brake

6-8 Barmain airsupply

I/P Converter

PR002.dsf

1/3/02 15


2. Pneumatic Installation

Connect main air supply (1) to air filter (2), air filter to I/P-converter (3), and I/P converter to brake cylinders (4)(see diagram below).

Recommended: install an air pressure gauge (or manometer) in line with the brake if the gauge is not present on the I/P converter.

3.3.3 Electrical Installation

1. I/P Converter

Connect cable from X-3000ce-UW controller to I/P converter (see diagram below):

1

23

5u 0.3u

4

PR003.dsf

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2

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4 5

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7

8

9 1

0 1

1 12

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7 1

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3 24

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8 2

9

30 3

1 3

2 3

3 34

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8 3

9 40

41

42 4

3 4

4 4

5 46

47

48

49 5

0 51

52

53

54 5

5 56

57

58

R1 R2 R3 R4 R5 R6

Ente r

-

+Back Sp ace

Down

Up

DO 4DO 3DO 2DO 1


00

PE

230

115 TENSION 0%

L N

Type : X-3000ce-UWVoltag e : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000

WD044.dsf

15

16 1

7

0V 4 - 20 mA

0 - 10VCable from controller to I/P Converter

Regulatedoutput:

I/P Converter

(+) (-)(PS)+24 V

*Connect if I/P converteruses a 24 VDC power supply.

0V

+24V

1 2

3

4

4 - 20 mA0V

Shield /Ground

*

16 1/3/02


2. Load Cells

Plug cable into load cell and connect cable to the X-3000ce-UW controller (see diagram below).

3. Connection of start/stop signal from machine main panel:

Note: For explanation of softstart, see Section 3.9.1, p. 30.

Connect cable between machine main panel and X-3000ce-UW. The signal must come from a relay with the following function:

a) The relay must:

• energize when machine starts running or moving• de-energize when stop is pressed or when machine comes to a complete

stop (zero speed signal).

b) From this relay use the opening function (NC). The relay contact must be closed at stop and open at start of operation (see Fig. 1):

R1 R2 R3 R4 R5 R6

En ter

-

+Ba ck S pace

D own

U p

DO 4DO 3DO 2DO 1


00

1

2

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2 5

3 54

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58

L N PE

T ype : X/D -300 0Serial no : 960034Voltage : 115V/23 0V ACCurrent : <200 mA

220

110

30 3

1 3

2 3

3 3

4 3

5 3

6 3

7 3

8 3

9 40

41

42

43

11 1

2 1

3 1

4

11

12 1

3 1

4

40 41

42

43

0VDC +2.5V

-2.5V

*Red *White *Black

*Color code for Montalvo standard cable

Cable from load cell 1

*Red *White *Black

-2.5V

+2.5V +Input

Shield / Ground- Input Cable from

load cell 2

Shield / Ground

0VDC

WD029.dsf

K100

K100

+24V

DI5Softstart/

1

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4 5

6

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9 1

0

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9

K100

1 (COM)

2 (NC)

MACHINE START

Fig. 1START

WD012.dsf

STOP

1/3/02 17


4. Connection of supply voltage to the X-3000ce-UW controller

Connect cable between machine main panel and X-3000ce-UW 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.

b) Connect cable in the machine main panel.

c) Remove fuse from the fuse holder on the printed circuit board (PCB) if fuse is already installed.

d) Connect cable in the X-3000ce-UW (see diagram below).

e) Turn on machine main panel again.

f) Using voltmeter, check connection of terminal points L, N and PE before inserting fuse.

g) Turn machine off.

h) Insert correct fuse and turn machine on.

L N PE

L N PE

220

230

115

10 MM Max.

R1 R2 R3 R4 R5 R6

Enter

-

+Back Space

Down

Up

DO 4DO 3DO 2DO 1


00

1

2

3

4 5

6

7

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0 1

1 12

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8 29

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7 4

8 4 9

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51 5

2 5

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56 5

7 58

L N PE

Type : xxxxxxxxxxSerial no : xxxxxxxxVoltage : xxxxxxxxxCurrent : xxxxxxx

230

115

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9 40

41 4

2 4

3

11 1

2 13

14

Voltage Switch ( In 230 v Position )

Fuse Holder

FUSE SIZE:115V -160mA T (slow blowing type) Dia. 5 - 20 mm230V - 80 mA T (slow blowing type) Dia. 5- 20 mm

WD022.dsf

18 1/3/02


3.3.4 Web Tension Adjustment

1. Check that load cells are mounted and oriented properly. Refer to the load cell installation instructions.

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.

3. Apply power to the controller and let it warm up for at least 10 minutes.

4. With web removed and no tension applied to the sensing roller, adjust potentiometer R1 until analog tension meter reads zero. (If non-cabinet version is used, see digital display: tension should read 0%.) If value is below zero, turn R1 clockwise; if above, turn counterclockwise.

Note: R1 and R2 are 25-turn potentiometers, so many rotations may be required.

5. Thread a rope over the center of the tension-sensing roller following the exact path of the web. Make sure the rope extends at least one roller before and one roller after the sensing roller. Make sure the rope does not pass over any dead bars or non-freewheeling rollers. Fasten one end of the rope securely.

6. Attach a weight of known value to the other end of the rope. For best results, the weight should be at least 25% of the analog meter's full-scale value. A tension value below 0% with the weight hung indicates that the signal from the load cells is reversed. In the event of such a reversal, switch wires 12 & 14 and 41 & 43 on the terminal block. To eliminate friction, rotate rollers in the direction of the weight.

For cabinet and non-cabinet versions of the controller, see section 2.2, p. 9.

MANUAL

MANUAL/ AUTO

AUTO

TENSIONOFF / ON

T

20 80

50

20 80

50

20

OUTPUT

IL004.dsf

R1 R2 R3 R4 R5 R6

+Back SpaceUp

DO 4DO 3DO 2DO 1

00

Load cell

IL005.dsf

1/3/02 19


7. Adjust potentiometer R2 until analog meter reading is identical to the hanging weight. (If non-cabinet version is used, see digital display: tension will appear as a percentage value [%]).

8. Remove weight and check that tension meter returns to zero. If not, repeat steps 4 to 7.

9. If a second calibration range is used, repeat steps 4 to 8, using potentiometer R3 for calibration of second range.

R1 R2 R3 R4 R5 R6

+Back SpaceUp

DO 4DO 3DO 2DO 1

00

Load cell KG

IL006.dsf

20 1/3/02

3.4 Startup and Adjustment.

3.4 Startup and Adjustment.

The system is now ready to start.

1. Scroll to the password menu. Press enter, then up arrow to change display to 5. Press enter again, then down arrow key. Password 5 allows access to setup menu.

2. Scroll to the parameter [Gain] under the setup menu.

3. Install a small roll on the unwind stand.

4. Run machine at low speed and adjust [Gain]until web tension is steady but still responsive to variations.

5. Stop machine and go to parameter [Ratio] under the setup menu.

6. Install a large roll in the unwind stand.

7. Run machine at low speed and adjust [Ratio] until web tension is steady but still responsive to variations.

8. Scroll to [Softs Menu] and adjust [Softs Time] so that it fits the machine's deceleration ramp.

• If signal for start/stop (terminal 34) goes low before machine reaches zero speed, enter time between maximum and zero speed in parameter [Softs Time].

• If signal to start/stop (terminal 34) goes low only when machine reaches zero speed, set time in parameter [Softs Time]to 0.2 seconds.

Note: The Quick Setup Guide is intended to get the system up and running in a short period of time. To maximize system performance, please read entire manual.

Note: For complete instructions on keypad use, see Section 3.15, p. 59.

DiagnosticPasswordSetup Menu

Mode MenuRun ModeAmplifier0/4mALanguage

GainRatioP LevelD LevelSofts Menu

Start OutSofts Lev.Softs TimeHold Level

Anti MenuAnti.Src.Anti MaxAnti MinAnti Slope

Splce MenuSplice SrcSplice DelSplice LevSplice Tim

WebBr MenuWebbr Lev.Webbr Time

Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu

Range Dia MenuDia. Menu

Diamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter

Output2 MenuOut2 SrcOut2 SlopeOut2 ScaleOut2 Off

1/3/02 21


3.5 Basic Diagrams for Standard Application Non-cabinet Version

IL140.dsf

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3 2 4

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41

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3 4

4 4

5 46

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49 5

0 51

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53

54 5

5 56

57

58

R1 R2 R3 R4 R5 R6

Enter

-

+Back Space

Down

Up

DO 4DO 3DO 2DO 1


00

XXXXXXXX 0%

PE


230

115

L N

44 45 18 19 20 47 48 49

10 K

Autosetpoint

10 K

Manualsetpoint

V o lta g e0 - 10 V

TENSION output

46L N

Power supply115 / 230 VAC

34 36 6

Softstart Anticoast(Stop orzero speed)

(Fast stop)

- +

WD069.dsf

bla

ck

wh

ite

red

Loadcell1

Loadcell2

*Type 1 connector 3 pole MIL std. (a-c)*Type 2 connector 6 pole DIN std. (1-3)

bla

ck

wh

ite

red

1412 13

*a/1 *c/3*b/2 *a/1*c/3 *b/2

4143 42PE is connected to 0 VDC

31 33 32

Manual Tensionoff

Voltage0 - 10 V

- +

REGULATED output

15 16 17

4 - 20mACurrent

4

* * S e e

b e l o wn o t e

**Connect wire if converter uses24 VDC power supply

PE

22 1/3/02

3.5 Basic Diagrams for Standard Application

Cabinet Version

50

20 80

100%0

MANUAL AUTO

TENSION OFF/ON

AUTOM A N U A L

OUTPUT

50

20 80

100%0


IL007.dsf

WD073.dsf

bla

ck

wh

ite

red

Loadcell1

Loadcell2


bla

ck

wh

ite

red

1412 13

Multi cable

Multi connector

10 K

Manual

10 K

Autosetpoint

+10V

GN

D

+10V

GN

D TensionOff

GN

D

+10V

+24V

OutputTension

100 K

100 K

Front panel

4 517 19 12 13127 28 Multi connector

Manual

*a/1 *c/3*b/2 *a/1*c/3 *b/2

4143 42

34 36 6

Voltage0 - 10 V

- +

REGULATED output

15 16 17

4 - 20mACurrent

4

* * S e e

b e l o wn o t e

**Connect wire if converter uses24 VDC power supply

Softstart Anticoast(Stop orzero speed)

(Fast stop)

L N

Power supply115 / 230 VAC

PEPE is connected to 0 VDC

1/3/02 23


3.6 Complete Wiring Diagram

L N

Power supply115 / 230 Vac

Multi cable

main board

bla

ck

wh

ite

red

Loadcell1

Loadcell2


bla

ck

wh

ite

red

1412 13

*a/1 *c/3*b/2 *a/1*c/3 *b/2

4143 42

44 45

Voltage0 - 10 V

Current0 - 100uA

TENSION OUTPUT

46100 K

Multi connector27 28 1917

PE is connected to 0VDCPE

OPTIONS

10 K

Manualsetpoint**

10 K

Auto

10 K

SpliceLevel*

+10V

GN

D

+10V

GN

D

+10V

GN

D

Manual**Tension Second

Cal.**

GN

D

+10V

+24V

OPTIONS

OutputTension

100 K

100 K

Front panel

4 517 19 23 12 13127 28 Multi connector 14

OPTIONS

10 K

Manual

10 K

Auto

10 K

SpliceLevel*

+10V

GN

D

+10V

GN

D

+10V

GN

D Tension SecondCal.**

GN

D

+10V

+24V

OPTIONS

OutputTension

100 K

100 K

Front panel

4 517 19 23 12 13127 28 Multi connector 14

OPTIONS

10 K

Manual

10 K

Autosetpoint**

10 K

SpliceLevel**

+10V

GN

D

+10V

GN

D

+10V

GN

D TensionOff**

SecondCal.**

GN

D

+10V

+24V

OPTIONS

OutputTension

100 K

100 K

Front panel

4 517 19 23 12 13127 28 Multi connector 14

47 48 49 18 19 20

10 K

Manualsetpoint*

10 K

Autosetpoint*

+10V

GN

D

+10V

GN

D

Y 1 .0 Y 1 .1 Y 1 .2

EMERGENCY STOP

RANGE 1 RANGE 2

I/P-Converter

7 9 39

E-Stoprelay

4300mA 100mA 100mA24VDC

16 1517

4 - 20mACurrent

Voltage0 - 10 V

REGULATED output***Connect wire if converter uses

24 VDC power supply

* * * S e en o t eb e lo w

1

2

3

4 5

6

7

8

9 1

0 1

1 12

13

14

15 1

6 1

7 1

8 19

20

21

22 2

3 24

25

26

27 2

8 2

9

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9 40

41

42 4

3 4

4 4

5 46

47

48

49 5

0 51

52

53

54 5

5 56

57

58

R1 R2 R3 R4 R5 R6

Enter

-

+Back Space

Down

Up

DO 4DO 3DO 2DO 1


00

TENSION 0%

PE

Type : X3000ce-UWVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000

230

115

L N

WD005L.dsf

24 1/3/02

3.6 Complete Wiring Diagram

OPTIONS

Y 1 .3 Y 1 .4

RANGE 3 RANGE 4 or WEB BREAK

10 38

R e la y

50 51 52

10 K

SpliceLevel**

+10V

GN

D

31 332

Manual** TensionOff**

Secondcal.**

33

+24V

34 26

Anticoast Splice

36

Softstart(Stop orzero speed)

(Fast stop)

+24V

Proximity switches

OPTIONS

OPTIONS

5

+24 S 0V

3533 1

Web pulse Brake pulse

+24 S 0V

PNP PNP

** Analog signals (manual setpoint, auto setpoint and splice level) 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.

+24V

GN

D

24 25 27

10 K

input 0 - 10VdcAnalog diameter

GN

D

+10V

5553

Input 0-10VGain control

GN

D

5756

0-10VAnalog output 2

GN

D

2928

Output 4-20mA

GN

D

5856

Input 0-10V

GN

D

Volt

Amp.1223 13 14

100mA 100mA

50

20 80

100%0

50

20 80

100%0

MAN UEL/ AU TO

TE NSION OFF /ON

AUTOMAN UEL

OUTP UT

50

20 80

100%0

W D005R.dsf

1/3/02 25


3.7 Terminal Blocks

Note: jumpers that connect terminals 4 and 7 and 57 and 58, and that are shipped with the controller, do not appear in the diagram above.

1

2

3

4 5

6

7

8

9 1

0 1

1 1 2

13

14

15 1

6 1

7 1

8 19

20

21

22 2

3 24

25

26

27 2

8 2

9

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9 40

41

42 4

3 4

4 4

5 46

47

48

49 5

0 51

52

53

54 5

5 56

57

58

DI2 / SpliceDI4 / Sec. calibration+24VDI6 / Web Pulse DI8 / Anticoast+24V input for DO

DO2 / Range 1DO4 / Range 3

0VDC

Manual / DI1Tension OFF / DI3

+24V

+24V

Softstart / DI5Brake Pulse / DI7

Range 2 / DO3

-2.5V

-2.5V +2.5V

+2.5V

+Load cell input-Load cell input

+10V+10V

+10V

+10V-10V

Regulator output 4-20mARegulator output 0-10V

Tension output 0-10VTension output 0-100uA

Auto setpoint 0-10V

Taper setpoint 0-10VDiameter output calibrated 0-10V

Diameter/trim input +10V

4-20mA output from U/I converter Input for extra U/I converter 0-10 V

Extra analog output2 0-10V

External gain 0-10VSummation input 0-20V

Splice setpoint 0-10V

Manual setpoint 0-10V

0VDC

0VDC

0VDC

0VDC

0VDC

0VDC

0VDC

0VDC

0VDC

0VDC

0VDC

0VDC

0VDC

0VDC

0VDC

Web break or Range 4 / DO1

WD014.dsf

26 1/3/02

3.8 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.

Terminal Connection

12 -2.5 V Supply

13 +Load Cell Input

14 +2.5 V Supply

41 +2.5 V Supply

42 -Load Cell Input

43 -2.5 V Supply

11 1

2 13

14

15 1

6 17

40 4

1 42

43

44

45 4

6

*GREEN

LOAD CELLCABLE

0VDC+2.5V

-2.5V-INPUT

*RED*WHITE*BLACK

0VDC-2.5V

+2.5V+INPUT

*Colors refer to standard cables supplied by Montalvo

LOAD CELL 1 CABLE

0VDC+2.5V

-2.5V-INPUT

*RED*WHITE*BLACK

LOAD CELL 2 CABLE

0VDC-2.5V

+2.5V+INPUT

Connection for T-Series Idler, Live Head & UPB

Connection for N-Series Load Cells

11

1 2 1

3 1

4 15

16

17

40 4

1 42

43

44

45 4

6

*RED*WHITE*BLACK LOAD CELL 1

CABLE

0VDC+2.5V

-2.5V-INPUT

0VDC-2.5V

+2.5V+INPUT

*Colors refer to standard cables supplied by Montalvo.

Connection for Ribbon Head

100 ohm resistor

100 ohm resistor

40 4

1 42

43

11 1

2 13

14

40 4

1 42

43

44

45 4

6

11 1

2 13

14

15 1

6 17

*RED*WHITE*BLACK

*Colors refer to standard cables supplied by Montalvo

PE

PE

PE

1

2

3

4 5

6

7

8

9 1

0 1

1 12

13

14

1 5 1

6 1

7 1

8 19

20

21

22 2

3 24

25

26

27 2

8 2

9

30 3

1 3

2 3

3 3 4

35

36

37 3

8 3

9 40

41

42 4

3 4

4 4

5 46

47

48

49 5

0 51

52

53

54 5

5 56

57

58

R1 R2 R3 R4 R5 R6

Ent er

-

+Back Space

Down

Up

DO 4DO 3DO 2DO 1


00

TENSION 0%

PE

Type : X3000ce-UWVoltage : 115 / 230 V ACCurrent : <200 mAS. nr. : 3000

230

115

L N

T-Series Idler Shaft T/er-Series Live Roller

UPB-Series

N-Series

R-Series

WD006.dsf

1/3/02 27


3.8.2 Installation: Regulated Output

15 0VDC Common signal (GND) for regulated voltage or current output. Connects to input ground of the converter.

16 Regulated Current Regulated 4–20 mA current signal to an I/P or other converter.

17 Regulated Voltage

Regulated 0–10 V output. Can be used for a 0–10V I/P or other converter. Can control motor drives operating in the torque mode. Maximum load: 5 mA.

4, 33, 36=24 V Supply Unregulated 22 to 28 volt DC supply for external use. Maximum load: 250 mA.

1, 8, 11, 15, 18, 21, 24, 28, 30, 37, 40, 44, 47, 50, 53, 56 = 0VDC

Common for signal (GND) and contact inputs and outputs

Wiring Diagram for I/P Converter and P-3000 (signal = 4-20 mA)

Wiring Diagram for I/P Converter and P-3000ce (signal=4-20 mA and 24 V supply)












15

16 1

7

0 V4 - 20 mA

0 - 10 VCable from controller to I/PConverter or P-3000

Regulatedoutput:

I/P ConverterP3000

Plug

WD045.dsf

Shield /Ground

1

2

3

4 5

6

7

8

9 1

0 1

1 12

13

14

15 1

6 1

7 1

8 19

20

21

22 2

3 24

25

26

27 2

8 2

9

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9 40

41 4

2 43

44

45

46 4

7 4

8 49

50

51 5

2 5

3 54

55

56 5

7 5

8

R1 R2 R3 R4 R5 R6

E nter

-

+Back Spa ce

Down

Up

DO 4DO 3DO 2DO 1


00

XXXXXXX 0%

PE


230

115

L N

0 V4 - 20 mA

(-) GND(+) Signal

15

16 1

7

0 V4 - 20 mA

0 - 10 VCable from controller to I/P Converter or P3000ce

Regulatedoutput:

I/P ConverterP3000ce

Plug

0 V

+24 V

1

2 3

4

Shield /Ground

1

2

3

4 5

6

7

8

9 1

0 1

1 12

13

14

15 1

6 1

7 1

8 19

20

21

22 2

3 24

25

26

27 2

8 2

9

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9 40

41

42 4

3 4

4 4

5 46

47

48

49 5

0 51

52

53

54 5

5 56

57

58

R1 R2 R3 R4 R5 R6

Enter

-

+Back Spa ce

Down

Up

DO 4DO 3DO 2DO 1


00

XXXXXXX 0%

PE

Type : X-XXXXce-XXVoltage : 115 / 230 V ACCurrent : <200 mAS. nr . : 3000

230

115

L N

WD046.dsf

0 V4 - 20 mA

+24 V(-) GND

PS

(+) Signal

28 1/3/02


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.

L Supply Voltage

N Supply Voltage

PE Ground

L N PE

L N PE

220

230

115

10 MM Max.

R1 R2 R3 R4 R5 R6

Enter

-

+Back Space

Down

Up

DO 4DO 3DO 2DO 1


00

1

2

3

4 5

6

7

8

9 1

0 1

1 12

13

14

15 1

6 1

7 1

8 19

20

21

2 2 2

3 2

4 25

26

27 2

8 29

44

45

46 4

7 4

8 49

50

51 5

2 5

3 54

55

56 5

7 58

L N PE

Type : xxxxxxxxxxSerial no : xxxxxxxxVoltage : xxxxxxxxxCurrent : xxxxxxx

230

115

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9 40

41 4

2 4

3

11 1

2 13

14

Voltage Switch ( In 230 v Position )

Fuse Holder

FUSE SIZE:115V -160mA T (slow blowing type) Dia. 5 - 20 mm230V - 80 mA T (slow blowing type) Dia. 5- 20 mm

WD022.dsf

1/3/02 29


3.9 Digital Input: Standard Functions

3.9.1 Softstart (Terminal 34)

Softstart input has two purposes:

• To stop the regulator when the machine is not running (hold mode).• To give the machine a soft startup.

When machine is running and this input signal is activated, the output level will be stored. This level will then be used for [Hold Level]and for the next startup.

In HOLD MODE, output is at a constant [Hold Level].

To compensate for roll inertia at next startup, the output must be reduced with a percentage of the stored level (typically 15 to 25%).

Running Example:

Machine is stopping

When this input is activated by 24 VDC, the controller switches to STOP MODE.

In STOP MODE the controller is still regulating until the time [Softs Time] has run out.

Machine has ramped to stop

When time has run out, controller changes to HOLD MODE.

In HOLD MODE, controller is not regulating and the desired output is set to a constant level = [Hold Level].

([Hold Level]= Stored level +%).

Machine is starting

When input is deactivated by removing +24 VDC, output will change to softstart level ([Softs Lev.]) and the regulator will begin to regulate from that level.

([Softs Lev.] = Stored level -%).












30 1/3/02


Cycles

SOFTS TIME

Run mode Stop mode

Speed

Time

Run mode

Machine

0 %

100 %

Controlleroutput

100 %

0 %Time

HOLDLEVEL

Fig. 1

Fig. 2

STOREDLEVEL

SOFTS LEV

Hold mode

SD006.dsf

1/3/02 31

Electrical Wiring
Parameter Setting and Adjustment:

1. [Start Out] (Start out)

[Start Out] is the output level with which controller starts when tension is switched on. This output is applied in two instances: 1) after power-up and 2) at TENSION ON. The output level varies in direct proportion to the setpoint. (Output=[Start Out] x setpoint)

Note: Set [Password]to 5 to access [Setup] menu.












START

STOP

K100

+24V

Softstart/D15

K100

1 (COM)

2 (NC)

MACHINE START

Fig. 2

K200

+24V

Softstart/D15

1

2

3

4 5

6

7

8

9 1

0

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9

K200

3 (COM)

4 (NO)

Zero speed signal from machine

MACHINESPEED ISZERO

Fig. 1

WD007.dsf

1

2

3

4 5

6

7

8

9 1

0

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9

K100

Fig. 1 (zero speed)

Fig. 2 (stop)

1010

S o ft t im e

R un m ode S top m ode

S p e e d

T im e

R u n m o de

M a c h in e

0 %

1 0 0 %F ig . 1

H o ld m o d e

S o ft t im e

SD003.dsf

32 1/3/02


To set the correct value:

a) Install a roll with maximum diameter and set the tension setpoint at 50%.

b) Start machine and run at a slow speed. Note output level when tension has become steady.

c) Stop machine and multiply output level noted in step b) by two (1/50% setpoint) and enter its value for [Start Out]. (For example, if noted output level is 30, set up 60). Use increase or decrease keys to change[Start Out]value.

Note: To see the new output level after changing [Start Out] parameter, switch tension off, then on again.

2. [Softs Lev.](Soft start level)

When the[Soft start] signal goes low (0VDC), the output changes to a percentage (%) of the stored level. This percentage is set up in this parameter.

To set the correct level:

a) Start machine at slow speed and stop after about 30 seconds.

b) Start machine again

c) Note tension.

d) If tension rises too much, decrease [Softs Lev.]; if tension drops too much, increase [Softs Lev.].

e) If adjustment in d) has been made, return to step b).












OUTPUT

50

20 80

100%0

50

20 80

100%0

MANUAL/ AUTO

TENSION OFF/ON

AUTOMANUAL

Output levelTension Tension setpointIL011.dsf

1/3/02 33


3. [Softs Time] (Time delay to stop)

If a stop signal is used and there is a delay between the time that the stop signal has been activated and the time that the machine reaches zero speed, enter the time as follows.

To set the correct time:

a) Run machine at maximum speed.

b) Measure time from activation of stop to zero speed.

c) Enter this time + 0.2 seconds in this parameter.

Note: If this time is longer than 10 seconds, use a zero speed signal.

d) Enter a short time when using a zero speed signal: minimum value is 0.1 seconds

4. [Hold level] (Hold level)

When [Softstart] signal is set high (Active high = +24 VDC), the controller stores the output level, but continues to regulate until the [Softs Time] has run out. If the time is set to the minimum value of 0.1 seconds, the output will change to hold level after 0.1 seconds. (Hold level = stored level +%.) If a longer time is set up, the output will change after that time. In hold mode, the output is at a constant hold level.

To keep the roll in the same position in hold mode, the stored level is increased by [Hold level] to create a holding output.

Hold level = Stored level.

Example of the output level in hold mode:

Hold Mode Menu: Hold level 100% => Stored level Hold Mode Menu: Hold level 150% => Stored level + 50%












34 1/3/02


3.9.2 Anti coast (Fast stop) (TERMINAL 6)

Use this signal if the machine has a fast stop function or if it stops with a short rampdown time.

To prevent a drop in tension, activate signal exactly when machine begins to ramp down (see Fig. 1). This will prevent a drop of tension during that time.

Fig. 2 below shows how tension will drop if this signal is not used.












TENSIONLEVEL

100 %

-100 % Time

Fig. 2

ANTICOAST

TENSIONDROPS

Speed

Time

Run mode

Machine

0 %

100 %

Hold mode

Anti-coastmode

Fig. 1

SD022.dsf

1/3/02 35


Stop signal is activated

When input is activated by 24 VDC, output increases to a higher level and then starts to regulate again. The level is set by the anticoast level parameter.

Anticoast is factory-set to use Source = OUTPUT.

Possible sources for anticoast:

Examples for which diameter source is best when production:

• Requires large rolls and low tension• Uses a great variety of materials

Note: set up and adjust diameter parameters in the diameter menu.

Electrical Wiring

Here is a typical example of how to connect the fast stop.

[OUTPUT]

The torque required for fast stop is calculated internally by the controller from the setpoint and the output. The result is a calculated diameter that can be scaled by an adjustable factor that fits the machine's actual rampdown time.

[DIAMETER]In some applications, the correct diameter cannot be calculated from setpoint and output. In such instances, diameter should be chosen as source.












START

STOP

K100

K100

+24V DI8 / Anticoast

1

2

3

4 5

6

7

8

9 1

0

3 0 3

1 3

2 3

3 34

35

36

37 3

8 3

9

K100

1 (COM)

2 (NC)

MACHINE START

(fast stop)

WD003.dsf

Stop signal10

Run mode Stop mode

Time

Run mode

SpeedMachine

0 %

100 %

Anticoast mode

SD005.dsf

36 1/3/02


Parameter Setting and Adjustment

1. [Anti.Src.] (Anti Source)

The source for the anticoast must be set up under the following parameter:

2. [Anti Max] (Anticoast maximum level)

Set up the maximum necessary level for the torque at fast stop with this parameter. See graph below.


a) Install a large roll. Set tension setpoint at about 50%.

b) Start machine and run it at maximum speed.

c) When tension has stabilized for 10 seconds, stop the machine with the function that activates the fast stop signal.

d) Note the tension.

e) Decrease [Anti Max]if tension rises; increase if tension drops.

f) If the adjustment has been made in step e), return to step b).

[Anti.Src.=OUTPUT]

The torque required for fast stop is calculated internally by the controller, from the setpoint and the output. The result is a calculated diameter that can then be scaled by an adjustable factor that fits the actual rampdown time on the machine.

[Anti.Src.=DIA.]

The torque required for fast stop is calculated internally by the controller from the actual diameter. The actual diameter is then scaled by an adjustable factor that fits the actual rampdown time on the machine.












Anti Max = 200% Anti Max = 100%

Anti Max = 50%

AnticoastTorque

Controlleroutput

100%

80%

60%

40%

20%

0%20% 40% 60% 80% 100%

Anticoast level (max.)

C&G001.dsf

1/3/02 37


3. [Anti Min] (Anticoast minimum level)

Set up the minimum necessary level for torque at fast stop with this parameter. See graph below.


a) Install a small roll and set tension setpoint at about 50%.




e) Decrease [Anti Min]if tension rises; increase if tension drops.

f) If the adjustment has been made in step e), return to step b).

Anti min = 20%

Anti min = 30%

Anti min = 0%

Controlleroutput

100%

80%

60%

40%

20%

0%20% 40% 60% 80% 100%

AnticoastTorque

Anticoast (min.) C&G002.dsf












38 1/3/02


4. [Anti Slope] (Anticoast slope) This parameter sets up the right slope for the torque at fast stop. See graph below.


a) Install a roll approximately 33% in diameter and set tension setpoint at 50%.




e) Increase [Anti Slope] if tension rises; decrease if tension drops.

f) If adjustment has been made in e), return to step b).












Anti Slope 1.0

2.0

3.0

100%

80%

60%

40%

20%

0%20% 40% 60% 80% 100%

Controlleroutput

AnticoastTorque

Anticoast Slope C&G003.dsf

1/3/02 39


3.9.3 Splice (DI2) (TERMINAL 2)

This function controls the regulator in splice sequence. The following sequence diagram shows a flying splice:

1. New roll is ready and in splice position when operator activates splice sequence. (Typically, new roll will be accelerated up to web speed.)

2. Splice arm moves down; new roll is spliced onto running web.

3. Knife cuts web from the old roll.

4. Knife and splice arm retract. Splice is finished.

In a splice sequence, output level must change from the regulated output level on the old (or expiring) roll to a new output level on the new roll. The output level on the expiring roll will normally be low, while on the new roll the output will change to a much higher level.

If diameter of a new roll is about the same at every splice, the splice level will always be the same. If the diameter that is being spliced varies to a great degree, the splice level will also vary every time. In a standard application, the splice level is set in a software parameter fixed at the same level for every splice. As an option, the splice level can be set up either from an external signal or from a potentiometer on the front of the cabinet version. The option should be used in cases in which splice levels vary to a great degree.

Flying splice unwinder

Knife 1

3 4

2

SD008.dsf












50

20 80

100%0

50

20 80

100%0

MANUAL/ AUTO

TENSION OFF/ON

AUTOMANUAL50

20 80

100%0

OPTIONS: Splice level

IL012.dsf

40 1/3/02


Electrical Wiring

Below is an example of a splice signal connection. Typically a knife signal is used.

Optional: wire external splice level according to Fig. 2, if needed.

In splice mode the regulator is held at a constant level [Splice Lev] for a time [Splice Time], and then starts regulating again from that level (see diagram below). Optional: A delay between the knife signal and the cutting of the web can be set up in the parameter [Splice Del], if required.












SPLICE

DI2Splice

1

2

3

4 5

6

7

8

9 1

0

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9

KNIFESIGNAL

Fig. 1

VALVEKNIFE

K200

3 (COM)

4 (NO)

K200

+24V

10 K

+10V

0 V

Splice levelinput 0 - 10V

5051

52

Fig. 2

0 V

Splice levelinput 0 - 10V50

5152

OR

+

WD016.dsf

output

Time

Regulated

0 %

Tension

0 %

Fig. 1

Time

TensionSetpoint

Splice

Knife signal or

DI2Splice /10

10splice button

TimeSpliceDelay Splice

Level

SD014.dsf

1/3/02 41



1. [Splice Src] (Splice source)

Set up the source for the splice level.

Note: splice level from the front of the cabinet and external splice level cannot be used at the same time.

2. [Splice Del] (Splice delay)

In the event of delay from activation of the knife signal to the cutting of the web, this time can be set up within this parameter.

3. [Splice Lev](Level from splice menu parameter)

[Splice Src = S. Lev]

The level for the splice is set up in the menu parameter for [Splice Lev]. A new output level is needed when the knife cuts the web. The new output level depends upon the diameter of the new roll. New rolls will typically be about the same diameter, in which case the level can be constant. To compensate for different setpoints, this output level varies in proportion to the setpoint. (Output = Splice Levx setpoint)

[NONE] Set up if splice is not used.

[S. Lev]

(Splice level is source.) With[S. Lev]as the source, the splice level is set up in a menu parameter. Choose this source if the diameter of the new roll is about the same at every splice.

[ANALOG]

(Analog source) With [ANALOG] as source, the splice level comes from an analog signal (0-10V). The analog signal can either be wired on terminal 51, or come from a potentiometer on the front panel in the cabinet version (see drawing below). Choose this source for large changes in the diameter of the new roll.

X-300010

K

+10V

Splice level 0-10V

0 V

Splice levelinput 0 - 10V

5051

52

+10V

10 K

0 V

boardMain

X-3000

boardFront panel

1.6 1.3 1.1

Operator&

controlpanel

50

20 80

100%0

50

20 80

1 00%0

MANUEL/ AUTO

TENSION OFF/ON

AUTOMANUEL

OUTPUT

Type: X3 000 -ce-UW SN: 34 55

Supplyvoltage: 1 15/230V 60/50 HzSupplycurre nt: < 0.5A

50

20 8 0

100 %0

WD042.dsf












42 1/3/02


See this example with the [S. Lev] parameter set to 75%.

• Setpoint at 100% will give 75% output.• Setpoint at 50% will give 37.5% output.• Setpoint at 10% will give 7.5% output.


a) Install a roll with maximum diameter and set tension setpoint at 50%.

b) Start machine at slow speed. Note output level when tension has stabilized.

c) Stop machine and multiply the noted output level by 2 (1/50% setpoint) and set [Splice Lev] to that value. (For example, if noted output level is 30%, set up 60% in this parameter).

4. Level from analog source

To get a perfect splice, record splice level, diameter, and tension. To find the right values:

a) Install a full roll with the required tension setpoint.

b) Start machine at a slow speed. Note output level when tension has stabilized.

c) Stop machine and write down diameter, tension, and output level. The noted output level should be the correct splice level for this diameter.

d) Perform steps a - c with different diameters and tension setpoints and list them as well.

[Splice Src = ANALOG](Analog Source)

The signal on terminal 51 can either come from the front of the cabinet version or from an analog input signal. 0 to10 VDC on this analog input will give 0 to 100% output. Once the knife cuts the web, a new output level will be needed. The new output level depends upon the diameter of the new roll.

Production: Tension setpoint: Splice level: Diameter:Paper (40 grams/25 lbs.) 35% 60% 100%

Paper (40 grams/25 lbs.) 35% 45% 75%

Paper (40 grams/25 lbs.) 35% 30% 50%

Paper (80 grams/50 lbs.) 60% 80% 100%












OUTPUT

50

20 80

100%0

50

20 80

100%0

MANUAL/ AUTO

TENSION OFF/ON

AUTOMANUAL

Output levelTension Tension setpointIL011.dsf

1/3/02 43


5. [Splice Tim] (Splice time)

During this time, output is set to a constant level before returning to automatic regulation. Typical setting for this parameter is about 1.0 seconds.

Checking Splice Settings:

a) Put a new roll in splice position.

b) Run machine at splice speed, and make a splice. Tension should resemble that represented in Fig. 2.












1

SD009.dsf

32

SD010.dsf

output

Time

Regulated

Tension

Fig. 2

Time

TensionSetpoint

Splice time Splice

level

Fig. 1

SD015.dsf

44 1/3/02


3.9.4 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.

3.9.5 Tension Off (DI3) (TERMINAL 32)

When activated by a 24 VDC input, the output goes to zero and the regulator is reset. This function is used at roll change. When input goes low, the regulator is set to the new roll parameter. (Start Out)

3.9.6 Second Calibration (DI4) (TERMINAL 3) (Option)

When activated by a 24 VDC input, the second tension calibration range must be used. Potentiometer R3 adjusts calibration for this range. Use this feature either for operation over a wide tension range or for two different web paths.

Sec. Calibration (DI4)

1

2

3

4 5

6

7

8

9 1

0

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9

Sec.cal.

+24V

WD152.dsf

1/3/02 45


3.10 Analog Signals: Standard Functions

Manual Potentiometers

47 0VDC Connects to the CCW terminal (1) of the MANUAL potentiometer. Use 10 kΩ potentiometer.

48 Manual 0 to 10 volt input corresponding from zero to maximum output in manual mode. Connects to the wiper terminal (2) of the MANUAL potentiometer.

49 10V Reference Reference voltage applied to the CW terminal (3) of the manual potentiometer. Total maximum load: 5 mA.

Auto Setpoint Potentiometer

18 0VDC Connects to the CCW terminal (1) of the AUTO potentiometer. Use 10 kΩ potentiometer.

19 Auto setpoint 0 to 10 volt input corresponding from zero to full scale tension in AUTO mode. Connects to the wiper terminal (2) of the AUTO potentiometer.

20 10V Reference Reference voltage applied to the CW terminal of the AUTO potentiometer. Total maximum load: 5 mA.

Splice Potentiometers

50 0VDC Connects to the CCW terminal (1) of the splice level potentiometer. Use 10 kΩ potentiometer.

51 Splice level Input for external signal if used to set output during splice mode. A 0 to 10 volt input corresponds from zero to maximum output.

52 10V Reference Reference voltage applied to CW terminal (3) of the splice level potentiometer. Total maximum load: 5 mA.

Tension Outputs44 VDC Common for tension outputs.

45 Tension 0 to 10V 0 to 10 volt output proportional to 0 to full-scale tension.

46 Tension 0 to 100µA 0 to 100 µA output proportional to 0 to full-scale tension.

15 1

6 1

7 1

8 19

20

21

22 2

3

44 4

5 46

47

48

49 5

0 51

52

+10V+10V

+10V

Regulator output 4-20mARegulator output 0-10V

Auto setpoint 0-10V

Splice Level 0-10V

Manual setpoint 0-10V

0VDC

0VDC 0VDC

0VDC

1

2

3

4 5

6

7

8

9 1

0 1

1 12

13

14

15 1

6 1

7 1

8 19

20

21

2 2 2

3 24

25

26

2 7 2

8 2

9

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9 40

41

42 4

3 4

4 4

5 46

47

48

49 5

0 51

52

53

54 5

5 5 6

57

58

R1 R2 R3 R4 R5 R6

Enter

-

+Back Space

Down

Up

DO 4DO 3DO 2DO 1


00

XXXXXXXX 0%

PE


230

115

L N

WD076.dsf

0VDC Tension 0 to 10V

Tension 0 to 100µA

46 1/3/02

3.11 Input and Output: Special Functions

3.11 Input and Output: Special FunctionsSpecial Functions

58 Input 0-10V for Current Converter Input for voltage to current converter. Converts 0-10V into 0-20mA/ 4-20mA, depending on setup.

57 Extra Analog Output2 +10V max 5mA. Used in special applications.

56 0VDC For extra analog output.

55 External Gain Input for external gain reference to the regulator. May be input from diameter calculator or other source. For special applications.

54 Summation

Extra summing input to regulator circuit (0-20 VDC). Used in intermediate applications where the tachometer signal is connected into the system. The signal must be galvanically isolated. For intermediate and special applications only.

29 Output 0-20mA/4-20mA Output from voltage to current converter. Converts 0-10V on terminal 58 into 0-20mA / 4-20mA, depending on setup.

26 -10 V Reference Reference supply for external use. -10V max 5mA.

Digital Inputs

35 Digital Input 6 24 VDC digital input from proximity switch or encoder on brake for diameter calculation. Maximum frequency 80 Hz.

5 Digital Input 5 24 VDC digital input from proximity switch or encoder on main machine for diameter calculation. Maximum frequency 800 Hz.

Digital Outputs7 Supply 24 VDC supply input for supply of digital outputs.

8 0VDC Common for digital output 1 & 2.

38 Digital Output 1 (web break) Digital output 24 VDC maximum 100mA. (Can also be used for range expander)

9 Digital Output 2 Digital output 24 VDC maximum 100mA. Normally used for range expander.

37 0VDC Common for digital output 3 & 4.

39 Digital Output 3 Digital output 24 VDC maximum 100mA. Normally used for range expander.

10 Digital Output 4 Digital output 24VDC maximum 100mA. Normally used for range expander.

1/3/02 47


3.12 Web Break

This digital output 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 softstart is low:

• (Softstart low = machine started).

This 10-second period allows startup with new rolls when little or no tension is present.

When web break is active, and tension goes below web break level longer than web break time, output will be activated (i.e., go high). See Fig. 1.












Time untilWeb break function is active

Speed

Time

Machine

0 %

Tension

0 %

Fig. 1

Web break time

Time

TensionSetpoint

Web breakLevel

Softstart / DI5

DO1Web break / 10

10

web breakis active

10 sec.

SD007.dsf

48 1/3/02

3.12 Web Break

Electrical Wiring

Provided below is a typical example of the web break connection.


To set parameters in the web break menu, scroll to web break menu under the setup menu:

1. [Webbr Lev] (Web break level)

Tension under this level will activate output after the web break time.

The factory setting of 5% applies to most applications.

2. [Webbr. Time] (Web break time)

This is the time that the tension has to be under the web break level before output is activated (goes high).

To adjust this parameter, the time should be:

• long enough to prevent small tension drops stopping the machine.• short enough to prevent minimum material waste before stop.

START

STOPDO1Web break /

1

2

3

4 5

6

7

8

9 1

0

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9

K100

1 (COM)

2 (NC)

MACHINE START

Fig. 1

K100 24Vdc

WD017.dsf












1/3/02 49


3.13 Range Expander of X-3000-ce-UW

Range expansion divides the torque capabilities of a braking system into multiple ranges. Only ranges required for a desired torque are active at any given time. This feature allows a braking system to run a much wider scope of materials and tension settings. Each combination uses the braking system to its maximum potential and efficiency.

With a normal braking system, each brake pad is connected in parallel to regulated air output. The pads may be divided into groups called ranges using the range expander, which requires a P-3000 RE Pneumatic Interface. There can be anywhere between 2 and 4 ranges. Each range is driven from a separate valve switch in the P-3000. Using this method, only the ranges required for adequate torque within the linear range of brake functionality are active. The range expander will automatically switch in the number of ranges that are required and raise or reduce pressure on the brake accordingly. This will maintain the same tension across ranges.

Possible applications include:

The range expander can operate by two possible modes, by output or by diameter:

Changing Ranges by Tracking Output Pressure

Output Mode. The range expander will change to a lower range when output pressure regulates below 20% [Dn Level] for more than 20 seconds (range time) or to a higher range when output pressure regulates over 80% [Up Level] for more

Large Web Tension Variance small rolls/light material through large rolls/heavy material on same machine.

Fast Stop With High Inertia Rolls large rolls with low tension

Standard vs. range expander brake system








Range Exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake MenuPads R1Pads R2Pads R3Pads R4Randomize

Range Dia Menu4->3 Dia3->2 Dia2->1 Dia

Dia. MenuDiamet.SrcP/Rev Rollmm/Pulse Min Diam.Max Diam.Fac. DiamDF AutoSetNew Roll DDiameter


Range Expander

Brake

P-3000 I/P Converteror

PR ES SU RE

PR005.dsf

50 1/3/02


than 20 seconds (range time). During a range shift, the pressure is changed outautomatically to keep the same torque on the brake.

Changing Ranges by Tracking Diameter

Diameter Mode. The range expander will change to a lower range when the roll diameter is smaller than the switching diameter, or change to a higher range shift-up when roll diameter is greater than switching diameter. The controller automatically calculates the best switching diameters based on brake geometry. During a range shift, the pressure is changed automatically to keep the same torque on the brake.

Illustration of diameter, range, and pressure changes during typical unwind cycle under output pressure control

Illustration of diameter, range, and pressure changes during typical unwind cycle under diameter control

0

10

20

30

40

Range 4-3( 133%)

Range 3-2( 150% )

Range 2-1( 200% )

Output pressure

Time

Range time

DN level (20%)

Range Range time

100%

0%

time

SD016.dsf












SD017.dsf

0102030

40

Range 4-3( 133%)

Range 3-2( 150% )

Range 2-1( 200% )

Output pressure

Time

0

7991

100

Diameter (%)

63

Time

506070

Range time

1/3/02 51


Electrical Wiring

Without Emergency Stop

With Emergency Stop












Y5 Y1 Y2 Y3 Y4

EMERGENCY STOP

RANGE 1 RANGE 2 RANGE 3 RANGE 4

GND

WD010.dsf

3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9

1 2 3 4 5 6 7 8 9 1 0

3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9

1 2 3 4 5 6 7 8 9 1 0

Y5 Y1 Y2 Y3 Y4

EMERGENCY STOP

RANGE 1 RANGE 2 RANGE 3 RANGE 4

GND

K13 (COM)

4 (NO)EMERGENCY STOP

K1

EMERGENCY STOP RELAY

EMERGENCY STOP

WD009.dsf

52 1/3/02


Pneumatic Diagram


To set up parameters in the range expander menu, go to range expansion [Range Exp.] under the setup menu and do the following:

1. [RE Source] (range expander source)

Select one of three modes of operation for the range expander:

Note: The factory recommends the following setup:

• X-3000-ce-UW= [OUTPUT] or [DIA.]• D-3000-ce-UW=[DIA.]

Note: All remaining range expansion parameters must be set in Tension off mode.

2. [Ranges]

Select the number of ranges in your system: 2, 3 or 4.

3. [Start No.]

Select the starting range number: 1, 2, 3 or 4.

This is the range used after a range expander reset, which occurs after the following three conditions:

• Power has been applied to the controller• Tension has been switched on (new roll)• Controller has performed a splice operation.

Typical pneumatic connection

[NONE] Range expander not used

[DIA] Range expander runs under diameter control

[OUTPUT] Range expander runs under output pressure control

1 Air supply, 6-8 bar

2 Air filter

3 I/P converter, 0-6 Bar

4 Emergency stop valve

5 Manometer

6 Range 1 valve

7 Range 2 valve

8 Range 3 valve

9 Range 4 valve

1

2

3

45

6 7 8 9

Y1 Y2 Y3 Y4

Y5

Brake

5u 0.3u

PR006.dsf

1/3/02 53


Recommended: choose this value to reflect most frequently used material and roll diameter.

4. [Dn Level]when[RE source = OUTPUT]

If output level is below the [Dn Level] longer than [Range Time], the controller will switch down one range.

5. [Up Level]when[RE source = OUTPUT]

If output level is over the [Up Level] longer than [Range Time], the controller will switch up one Range.

6. [Range Time]

This is the delay time before the controller switches one of the ranges in or out. Following criteria will start the time delay:

[RE source = OUTPUT]

a) If output is under [Dn Level],[RE source = OUTPUT]

b) If output is over [Up Level][RE source=OUTPUT].

c) If a diameter switch-point is reached, [RE source=DIA] .

Note: In all conditions, controller must run in Auto mode before switching.

7. Enter [Brake Menu] sub-menu

For example: If [Ranges] = 2, only [Pads 1] and [Pads 2] should be set.

a) [Randomize YES] or [Randomize NO]

For equal wear of brake pads, randomize starting range.

If [Randomize YES] is selected, controller will rotate among the lowest ranges with equal numbers of brake pads. (Range 1 is the lowest range, Range 4 the highest.)

8. [Range Dia Menu]when (Re Source=DIA)

Note: This is only a readout parameter.

[Pads 1] [Pads 2] [Pads 3] [Pads 4]*

The number of brake pads in each of the possible ranges. You do not need to set values for ranges that are > [Ranges].

[4/3 Dia][3/2 Dia][2/1 Dia]

The best diameter switch points for the controller. The switch points are calculated from the information set up in the brake menu.












54 1/3/02

3.14 Diameter

3.14 Diameter

The diameter is in some cases useful and necessary, such as in the following instances:

• Control of gain• Reduction of tension (taper) on rewinder• Control of stop level at fast stop• Control of range expander in some special versions

The diameter can be calculated in 3 different ways:

1. Diameter Calculated From Tension and Output [LOCAL]

A function most often used in standard load cell applications. The diameter calculated is approximate, and not useful in applications requiring precise diameters.

2. Diameter Calculated From 2 Proximity Switches [PULSE]

The roll diameter is calculated during running by 2 proximity switches, one that senses roll revolutions (location 1) and the other that senses web speed (locations 2, 3 or 4). At the startup after roll change, the diameter of the new roll is calculated when the controller has received 2 pulses from the new roll. Pulse diameter calculations are recommended for machines with a wide web tension range; these calculations also improve fast stop function.

[LOCAL]The processor calculates a diameter from the tension and output. This way will not work in applications requiring a wide web tension range.

[PULSE] Diameter calculated from two digital input signals (2 proximity switches).

[ANALOG] Diameter from an external analog input signal.

Calculation of roll diameter

SD011.dsf

Brake

1. Brake pulse 2. Web pulse 3. Web pulse

4. Web pulse

1/3/02 55


a) Brake 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.

Note: Maximum input frequency must not exceed 80Hz.

b) Web Pulse (Terminal 5)

A proximity switch is mounted to sense the web length/pulse. The proximity switch can be installed in position 2, 3 or 4. The recommended web length/pulse is between 10 and 250 mm/pulse. For better resolution, use short distances between pulses.

Note: Maximum input frequency must not exceed 800Hz.

3. Diameter From External Analog Input [ANALOG]

An external analog signal can also be used. The signal must be a 0-10 VDC signal = 0-100% diameter. However, any signal between 2-6 VDC or 4-9 VDC can still be used because it is connected to a circuit with zero and span adjustments, after which the signal goes to the microprocessor. See the following diagram:

Warning: Do not place the proximity switch where it will be overheated by the brake.









Pads R1Pads R2Pads R3Pads R4Randomize




+10VX1.27

X1.25

X1.24Diameter input

++

+-ZERO

R4

R5 Span.

X1.23

Diameterinput AI6to micro-processor

Diameter calibrated

0VDC

WD021.dsf

56 1/3/02

3.14 Diameter

Electrical Wiring

Figures 1 and 2 describe the proper connection of the analog diameter signal and the 2 proximity switches:


To set up parameters in the diameter menu, go to diameter menu[Dia. Menu]in setup menu and do the following:

1. [Diamet Src] (Diameter source)

Select one of three modes for diameter.

a) If [LOCAL]is source, set up the following parameters:

1) Install a roll and measure its diameter (0-100%).2) Go to parameter “Diameter factor auto setup” [DF Auto set].3) Run machine at low speed until tension has stabilized for 10 seconds.4) Input actual diameter; press [Enter]. When [Enter] is pressed,

factor for the diameter will be calculated.

[LOCAL]The processor calculates the diameter from output and tension. (Factory setup)

[PULSE] Diameter is calculated from 2 proximity switches.

[ANALOG] Diameter from an analog input signal.

[Min Diam] (Minimum diameter). Minimum roll size must be set up in percentages (0 - 100%).

[Max Diam] (Maximum diameter). Maximum roll size must be set up in percentages (0 - 100%).

10 K

+10V

0 V

Diameterinput 0 - 10V

2425

27

Fig. 1

0 V

Diameterinput 0 - 10V

2425

27OR

+

1

2

3

4 5

6

7

8

9 1

0

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9Fig. 2

Proximity switches

+24V

+24 S 0V

Web pulse Brake pulse

+24 S 0V

PNP PNP

GND

WD020.dsf









Pads R1Pads R2Pads R3Pads R4Randomize




1/3/02 57


b) If [PULSE] is source, set up the following parameters:

c) If [ANALOG] is source, set up the following parameters:

1) Go to parameter [Diameter].2) Enter analog value for minimum diameter and adjust on potentiometer

R4 until 0% is displayed.

3) Enter analog value for maximum diameter and adjust on potentiometer R5 until 100% is displayed.

2. [New Roll D](New Roll Diameter)

New Roll Diameter is the diameter to which, after roll change, the controller is set until the calculation of the correct diameter by running again. The New Roll Diameter is automatically set to the maximum diameter when a new maximum diameter is entered. If application does not require maximum diameter, the parameter can be adjusted.

3. [Diameter](Diameter)

The current calculated diameter based upon previously set parameters.

[P/rev Roll] The number of pulses per revolution on the roll.

[mm/Pulse] Mm between pulses on the main machine.

[Min Diam] Minimum roll size in mm.

[Max Diam] Maximum roll size in mm.

[Min Diam] Minimum roll size in percentages (0 - 100%).

[Max Diam] Maximum roll size in percentages (0 - 100%).












R1 R2 R3 R4 R5 R6

+Back SpaceUp

DO 4DO 3DO 2DO 1

00

IL014.dsf

R1 R2 R3 R4 R5 R6

+Back SpaceUp

DO 4DO 3DO 2DO 1

00

IL015.dsf

58 1/3/02

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. The controller starts in scroll mode. A submenu is any menu below the current menu. A parent menu is any menu above the current menu.

Example: in the following instance, the user increases the value of [Softs Time] to 3.0 seconds. With the controller displaying [Diagnostic], the required steps are as follows:

a) Press Down (↓) until [Setup Menu] appears on the display. Press Enter (↵) to enter the submenu.

b) Press Down (↓) until[Softs Menu]appears on the display. Press Enter (↵) to enter the submenu.

c) Press Down (↓) until [Softs Time] appears. Press Enter (↵) to edit the parameter. (The cursor will blink.)

d) Press Up or Down [↑↓] until 3.0 appears on the display.

e) Press Enter (↵) to store change.

Scroll Mode

Up↑: Move to previous menu item.

Down↓: Move to next menu item.

Back Space←: Move to parent menu.

Enter↵: Enter menu if a submenu, or change to edit mode if a numeric or textual parameter.

Edit Mode Up ↑ : Increase numeric parameter value or move to previous textual parameter value.

Down ↓: Decrease numeric parameter value or move to next textual parameter value.

Back Space←: Cancel edit, returning to previous value.*

Enter↵: Store edit and return to scroll mode.

*Note: Back Space does not apply to "live" edit parameters. In a live edit parameter, the value is automatically stored when a change is made: the previous value cannot be returned to.

Enter

-

+Back Space

Down

Up

Enter

-

+Back Space

Down

Up

↓Diagnostic↓Password↵Setup Menu

↵Softs Menu

↓Start Out↓Softs Lev.↵Softs Time

[↑↓] ↵

1/3/02 59


3.16 Menu Tree DiagnosticMain menu Submenu DescriptionDIAGNOSTIC Main menu

VERSION Software version

RUN MODE Shows the actual Run Mode

TENSION Analog input no. 2, tension -110% to 110%

SETPOINT Analog input no. 1, setpoint-110% to 110%

OUTPUT Analog input no. 8, output - 110% to 110%

I-LEVEL Analog input no. 3, integrator -110% to 110%

MANUAL Analog input no. 4, manual level -110% to 110%

SPLICE Analog input no. 5, splice level -110% to 110%

SUMMATION Analog input no. 7, summing input 0 to 110%

GAIN Potentiometer level 0-63 steps

RATIO Potentiometer level 0-63 steps

DIAMETER Calculated diameter 0 -100%

ANALOG OUT2 Shows level on the extra analog output

PASSWORD Password gives access to setup and factory menus. To enter SETUP menu, use password 5

60 1/3/02

3.17 Menu Tree

3.17 Menu Tree

Please note that not all menus appear all of the time. Menus either irrelevant to the mode to without the correct password will not appear

DiagnosticVersionRun ModeTensionSetpointOutputI-LevelManualSpliceSummationGainRatioDiameterOutput2

PasswordSetup Menu(access with Pass-word 5)

Mode MenuRun ModeAmplifier0/4mA

LanguageGainRatioP LevelD LevelSofts Menu



Splce MenuSplice SrcSplice DelSplice LevSplice Time


Range exp.RE SourceRangesStart No.Dn LevelUp LevelRange TimeBrake Menu Pads 1 Pads 2 Pads 3 Pads 4 Randomize

Range Dia Menu 4->3 Dia 3->2 Dia 2->1 Dia



1/3/02 61


3.18 Setup Menu

Main Menu Submenu 1 Submenu 2 Description Enter

SETUP MENU Main menu R

MODE MENU R

RUN MODE Load cell unwind, X UW R

AMPLIFIER x1 or x10 preamplifier E

0/4 mA Output 0-20mA or 4-20 mA E

LANGUAGE English, German, French, Spanish, Danish AE

GAIN System gain 0-63 AE

RATIO System ratio 0-63 AE

P-LEVEL Proportional level 0-63 AE

D-LEVEL Derivative level 0-63 AE

SOFTS MENU Submenu for softstart. Enter menu to change parameters. R

ANTI MENU Submenu for anticoast. Enter menu to change parameters. R

SPLCE MENU Submenu for splice. Enter menu to change parameters. R

WEBBR MENU Submenu for web break. Enter menu to change parameters. R

RANGE EXP. Submenu for range expander. Enter menu to change parameters. R

DIAM. MENU Submenu for calculation of diameter. Enter menu to change parameters. R

OUTPUT2 MENU Submenu for extra analog output Output2. Enter menu to change parameters. R

62 1/3/02

3.19 Hardware Adjustment and LEDs

3.19 Hardware Adjustment and LEDs R1 Zero Range Adjusts analog tension meter (or digital display) to zero with no load on the load cell (zero

adjustment) (see tension calibration procedure in Section 4.1, p. 64).

R2 Calibration Range Adjusts analog tension meter (or digital display) to show actual web tension.

R3 Calibration Range Adjusts analog tension meter (or digital display) to show actual web tension on the high scale during use of a second calibration range.

R4 Diameter Zero Range Adjust until 0 is displayed in DIAMETER message (refer to diameter calibration in Section 3.12).

R5 Diameter Calibration Range Adjust until actual diameter is shown in the DIAMETER message (refer to diameter calibration in Section 3.12).

R6 Summation Input Calibration Not used in X-3000ce-UW.

R1 R2 R3 R4 R5 R6

Enter

-

+Back S pace

Down

Up

DI 6DI 5DI 4DI 3DI 2DI 1

DI 7DI 8

00

DO 4

DO 1DO 2DO 3

1

2

3

4 5

6

7

8

9 1

0 1

1 12

13

14

15 1

6 1

7 1

8 19

20

21

22 2

3 2

4 25

26

27 2

8 29

44

45

46 4

7 4

8 49

50

51 5

2 5

3 54

55

56 5

7 58

L N PE

TENSION 45 %

Type : X/D-3100Serial no : 960034Voltage : 115V/230V ACCurrent : <200 mA

220

110

30 3

1 3

2 3

3 34

35

36

37 3

8 3

9 40

41

42

43

11 1

2 13

14

R1 R2 R3 R4 R5 R6 R1 = Zero Calibration (Load cell Input)R2 = Range Calibration 1 (Load cell Input)R3 = Range Calibration 2 (Load cell Input)(See 4.1 Tension Calibration)

R4 = Zero Calibration (Diameter Input)R5 = Range Calibration (Diameter Input)(See 3.13 Diameter)

R6 = Summation Range Calibration(Not used in D- or X-3000ce-UW)

Potentiometers

DI 6DI 5DI 4DI 3DI 2DI 1

DI 7DI 8

DO 4

DO 1DO 2DO 3

DO4 = Range 3 (Range expander) Terminal 10DO3 = Range 2 (Range expander) Terminal 39DO2 = Range 1 (Range expander) Terminal 9DO1 = Range 4 (Range expander) or Web Break Terminal 38

Digital Output

DI8 = Anticoast Terminal 6DI7 = Roll Pulse Terminal 35DI6 = Web Pulse Terminal 5DI5 = Softstart Terminal 34 DI4 = Second cal. Terminal 3DI3 = Tension off Terminal 32DI2 = Splice Terminal 2DI1 = Manual Terminal 31

Digital Input

IL003.dsf

1/3/02 63

4 Calibration

4 Calibration

4.1 Tension Calibration

1. Check that load cells are mounted and oriented properly. Refer to the load cell installation instructions.

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.

3. Apply power to the controller and let it warm up for at least 10 minutes.

4. With web removed and no tension applied to the sensing roller, adjust potentiometer R1 until analog tension meter reads zero. (If non-cabinet version is used, see digital display: tension should read 0%.) If value is below zero, turn R1 clockwise; if above, turn counterclockwise.

Note: R1 and R2 are 25-turn potentiometers, so many rotations may be required.

5. Thread a rope over the center of the tension-sensing roller following the exact path of the web. Make sure the rope extends at least one roller before and one roller after the sensing roller. Make sure the rope does not pass over any dead bars or non-freewheeling rollers. Fasten one end of the rope securely.

6. Attach a weight of known value to the other end of the rope. For best results, the weight should be at least 25% of the analog meter's full-scale value. A tension value below 0% with the weight hung indicates that the signal from the load cells is reversed. In the event of such a reversal, switch wires 12 & 14 and 41 & 43 on the terminal block. To eliminate friction, rotate rollers in the direction of the weight.

For cabinet and non-cabinet versions of the controller, see section 2.2, p. 9.

MANUAL

MANUAL/ AUTO

AUTO

TENSIONOFF / ON

T

20 80

50

20 80

50

20

OUTPUT

IL004.dsf

R1 R2 R3 R4 R5 R6

+Back SpaceUp

DO 4DO 3DO 2DO 1

00

Load cell

IL005.dsf

64 1/3/02

4.2 Regulation Parameter, Gain, Ratio, P and D

7. Adjust potentiometer R2 until analog meter reading is identical to the hanging weight. (If non-cabinet version is used, see digital display: tension will appear as a percentage value [%]).

8. Remove weight and check that tension meter returns to zero. If not, repeat steps 4 to 7.

9. If a second calibration range is used, repeat steps 4 to 8, using potentiometer R3 for calibration of second range.

4.2 Regulation Parameter, Gain, Ratio, P and D

Gain. At small roll diameters, adjusts speed of regulator's response to errors. The parameter can be adjusted in a range of 0 to 63 steps. The higher the value, the faster the reaction to errors. Not recommended: parameters lower than 5.

Note: To access setup menu, scroll to [Password] and enter 5.

Ratio. At large roll diameters, the ratio adjusts speed of regulator's response to errors. The parameter can be adjusted in the range of 0 to 63 steps. The higher the value, the faster the reaction to errors. Not recommended: parameters lower than 10.

P-level. Proportional gain level of the PID regulator. The parameter can be adjusted in a range of 0 to 63 steps. The higher the value, the bigger the P- level in the PID regulator.

D-level. Derivative gain level of the PID regulator. The parameter can be adjusted in a range of 0 to 63 steps. The higher the value, the bigger the D -level in the PID regulator.

Note: for load cell controllers, D-level is normally set at 0.

R1 R2 R3 R4 R5 R6

+Back SpaceUp

DO 4DO 3DO 2DO 1

00

Load cell KG

IL006.dsf












1/3/02 65

4 Calibration

4.3 Tuning

1. Calibrate load cells as described in Section 4.1.

2. If used, set up range expander before running.

3. If used, set up diameter at diameter menu before running.

4. Tune with machine running at low speed. Place a small roll in the unwind stand, and adjust [Gain] until tension has stabilized but is still responsive to errors.

5. Place a large roll in unwind stand and adjust [Ratio] until tension has stabilized but is still responsive to errors.

6. Scroll to [Softs Menu] and adjust the start out, soft start level and soft start time to fit machine acceleration and speed.

7. If anticoast is used, scroll to [Anti Menu] and adjust level to fit machine deceleration time.

8. If used, set up and adjust web break or splice.












66 1/3/02

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 Factory Min. Max. UNITValue: Setting:

Mode Menu Mode X-UNWAmplifier X10 X1 X100 / 4 mA 4 mA 0 4

Language ENGLISGain 20 0 63Ratio 31 0 63P Level 30 0 63D Level 0 0 63Softs Menu Start Out 50 1 100 %

Softs Lev. 90 0 200 %Softs Time 5.0 0.1 99.9 SHold Level 100 0 200 %

Anti Menu Anti. Src. OUTPUTAnti max 50 0 500 %Anti min 2.0 0.0 20.0 %Anti Slope 2.7 0.0 3.0 %

Splce Menu Splice Src NONE Splice Del 0.2 0.0 1.0 SSplice Lev 50 0 200 %Splice Tim 1.0 0.5 5.0 S

WebBr Menu Webbr Lev. 5 -95 25 %Webbr Time 2.0 1.0 5.0 S

Range Exp. RE Source NONERanges 1 1 4Start No. 1 1 4Dn Level 20 0 100 %Up Level 80 0 100 %Range Time 20 1 60 SBrake Menu Pads R1 1 1 10

Pads R2 1 1 10Pads R3 1 1 10Pads R4 1 1 10Randomize YES

Range Dia Menu 4->3 Dia 83 0 100 %3->2 Dia 56 0 100 %2->1 Dia 28 0 100 %

Dia. Menu Diamet.Src LOCAL*P/Rev Roll 1 1 900 pulse*mm/Pulse 50 1 900 mmMin Diam. 10 0 500Max Diam. 100 0 2250**Fac. Diam 200 0 1000 %**DF AutosetNew Roll D 100 0 2250Diameter %

Output2 Menu Out2 Src DIAOut2 Slope 1.0 1.0 3.0Out2 Scale 100 0 200 %Out2 Off 0 0 100 %

Parameter Name:

1/3/02 67

5 Operation

5 OperationWeb Tension Meter

Displays actual web tension from 0 to 100%. Scale as required for application.

Output Meter

Displays regulated output from 0 to 100%. For best controller performance, output should be as high as possible at maximum roll size. With Montalvo brakes, activate or de-activate friction pads to adjust torque capacity.

Mode Switch - Auto/Manual

Used to select either AUTOMATIC (closed loop) or MANUAL (open loop) mode of operation.

Tension Switch

Used to turn regulator output off and on.

Low/High Scale Switch (optional)

Selects calibration range and meter scale in use.

Manual Potentiometer

Sets output of the controller when in MANUAL mode. No automatic regulation is done while in manual, so the operator must make constant adjustments to maintain the correct tension level. Also, there is no regulation of the range expander.

Auto Potentiometer (Setpoint)

Sets desired setpoint of controller when in AUTO mode. In automatic the actual web tension is compared to the desired tension (setpoint). The output is automatically adjusted to maintain set tension. Output changes proportionally with roll diameter and other factors that may affect web tension. The AUTO setpoint can be adjusted from 0 to 100% of the maximum displayed tension.

Auto/Manual Switching

When switching from MANUAL to AUTO, controller starts at the manual output, then regulates to the output required for automatic control. When switching from AUTO to MANUAL, controller immediately changes from AUTO to MANUAL set value. This may cause large tension changes. To avoid this, note the output while running in automatic. Set the MANUAL potentiometer to the approximate percentage of the auto output to maximum output. For example, if the auto output is 50% of the maximum, set the manual output potentiometer to 50%.

Soft Start

When controller receives a signal for machine to stop, after soft start delay time it switches into soft start mode. When machine is started, controller automatically switches into the auto mode. Soft start prevents the machine from starting with the output at maximum if the web has been slack during a stop.

68 1/3/02

5 Operation

Splice Level Potentiometer (Optional)

Sets the new roll starting output after splice.

Power Diode

The green LED indicates that the unit is on.

50

20 80

100%0

MANUAL AUTO

TENSION OFF/ON

AUTOM A N U A L

OUTPUT

50

20 80

100%0


IL007.dsf

1/3/02 69

6 Troubleshooting

6 Troubleshooting

Note: Diagram shows all possible functions for this circuit board. Some, however, are either not used in this configuration, or are available only as options at an additional cost. Consult factory for further details.

UI

0/4-

20 m

A

Opt

iona

l 0-1

0V in

put

to 0

/4-2

0 m

A ou

tput

1.58

1.29

-++

x1/x

10

+-ZE

RO

R1

R2

CAL

. 1

R3

CAL

. 2+2

.5V

-2.5

V

ab c

abc

Load

cell

1Lo

adce

ll 2

1.14

,41

1.42

1.13

1.12

,43

Load

sen

sor

rolle

r

Tens

ion

outp

ut 0

-10V

Tens

ion

outp

ut 0

-100

uAEx

tern

al te

nsio

n in

put

Tension AI 2

Cal

. sel

ect

DO

+10V

+10V

1.20

1.19

1.18

1.23 1.22

1.21

Tape

r %

Auto

setp

oint

X++

Rem

ote

setp

oint

AO1

Setp

oint

inpu

t AI1 - +

0VD

C

+10V

+10V

1.49

1.48 1.47

1.52 1.51

1.50

Splic

e in

put

Man

ual

setp

oint

Man

ual i

nput

AI4

Splic

e in

put A

I5

Opt

iona

l ana

log

outp

ut0-

10V

1.57

Anal

og o

utpu

t AO

4

+10V

1.27 1.25

1.24

Dia

met

er in

put

++

x1/x

10

+-ZE

RO

R4

R5

CAL

.

1.23

Dia

met

er in

put A

I6

Dia

met

er c

alib

rate

d

XI P D

Gai

n

Rat

io

P D

Sum

mat

ion

inpu

t1.

53

1.54

R6

SUM

MAT

ION

SUM

MAT

ION

IN

PUT

AI7

DIS

PLAY

16

CHA

R.

EPRO

M

RAM

DIG

IPO

TEE

PRO

M

RS48

5DI

GIT

AL

CONT

ROLL

ER

I/O INTERFACE

+24V

DC

DI1

1.4,

33,3

6

1.31

DI2

1.2

DI3

1.32

DI4

1.3

DI5

1.34

DI6

1.5

DI7

1.35

DI8

1.6

1.1,

30

Supp

ly D

O1.

7

DO

11.

38

DO

21.

9

DO

31.

39

DO

41.

10

1.8,

37

1.57 1.16

1.17

Anal

og o

utpu

t

Cur

rent

out

put

Reg

ulat

ed o

utpu

t

Tota

l out

put A

I8

1.56 1.15

IntegraterAI3

Exte

rnal

gai

n1.

55

+10

V

Pow

er s

uppl

yIn

put :

115/

230

V A

CO

utpu

t :+5

VDC

+/- 2

.5 V

DC

+/- 1

5 VD

C+2

4 VD

C

10.L

10.N

10.P

E

UI

X-30

00ce

Blo

ck D

iagr

am

0VD

C

0VD

C

0VD

C

0VD

C

0VD

C

0VD

C

0VD

C

0VD

C

0VD

C

1.45

1.46

WD011.dsf

70 1/3/02

6 Troubleshooting

If use of the X-3000ce-UW controller is no longer required, dispose of it according to regulations in force at the time.

For service, please contact:

Symptom Cause Check for

Web tension unstable both in AUTO and MANUAL modes...

Mechanical problemBad roll, bad bearings, bent shafts, worn gears, missing teeth, loose chains or belts, line speed variations, brake, clutch or drive problem.

Pneumatic problem Fluctuating air input, air leaks, water or oil in air lines.

Web tension and output stable in MANUAL, but unstable in AUTO...

Tuning problem Check regulator tuning. See Section 4.3, "Tuning‚" p. 66.

Regulator problem Check terminal points - if faulty, consult factory or replace circuit board.

Converter problem If signal voltage OK, replace converter.

Web stable in manual, but tension meter reading unstable...

Load cell problem Loose load cell mounting, cables, plugs, or unbalanced roll.

Tension meter Defective meter, loose connections.

Regulator problem Check + 2.5 V supply, tension output at 1.45.

Tension meter fails to read zero when web is slack...

Load cell problem Faulty or improperly installed load cells.

Adjustment problem See Section 4.1, "Tension Calibration‚" p. 64.

Web tension too low both in AUTO and MANUAL modes...

Pneumatic problem Check input air pressure and for air leaks. I/P converter may be defective.

Regulator problem Check terminal points - if faulty, consult factory or replace circuit board.

Brake/drive problem Brake/clutch too small, not enough pads activated, motor too small, drive current limit set too low.

Unwind - Tension increases at small roll diameters both in AUTO and MANUAL modes...

Mechanical problem Bearings in unwind defective, too much friction.

Pneumatic problem I/P converter may be defective.

Regulator problem Check terminal points, replace regulator if defective.

Brake problem Brake too large, too many pads activated.

The Montalvo Corporation50 Hutcherson DriveGorham, ME 04038 USATel. (207) 856-2501Fax. (207) 856-2509

Email: [email protected] site: www.montalvo.com

Danarota Technic A/SGI. Skartved 5 DK-6091 Bjert, DenmarkTel. +45 75 57 27 11Fax +45 75 57 29 97

1/3/02 71

http://www.montalvo.com

http://www.montalvo.com

The Montalvo Corporation • 50 Hutcherson Drive, Gorham, Maine 04038 USA • Email: [email protected] • www.montalvo.comTel: (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-UW © 2001 MONTALVO

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