Cleveland Motion Controls MWP-12663 User Manual

INTERMEDIATE TENSION CONTROLLER

MWP – 12663

Instruction Manual

AO-70174 (Rev BA)

Table Of Contents

General Description .............................................................................................................4

Intermediate Drive System ...................................................................................................................4

Quickstart ............................................................................................................................. 5

Installation ............................................................................................................................ 6

Cabinet Installation ...............................................................................................................................6

PCB Link Positions ..............................................................................................................6

Controller Connections........................................................................................................ 7

Transducer Connections ..................................................................................................... 8

Intrinsically Safe Transducer Connections for Hazardous Area Installations.......................................8

Machine Sequence Logic and Connections, Digital Inputs ..................................................................9

Digital Output Connections ...................................................................................................................9

Power Supply Connections.................................................................................................................10

Tacho Connections .............................................................................................................................10

Encoder Connections .........................................................................................................................10

Length Counter ...................................................................................................................................10

Batch Hold ..........................................................................................................................................10

System Set Up .................................................................................................................... 11

Machine Parameters........................................................................................................... 12

Language ............................................................................................................................................13

Unit system .........................................................................................................................................13

Transducers before or after main motor .............................................................................................13

Output trim only...................................................................................................................................13

Output range .......................................................................................................................................13

Start in control screen .........................................................................................................................13

Enable MAN / AUTO / OFF keys ........................................................................................................13

Dual tension range..............................................................................................................................13

Minimum tension.................................................................................................................................13

Output level bias .................................................................................................................................14

Output level limit .................................................................................................................................14

Set point ramp rate .............................................................................................................................14

Display damping time .........................................................................................................................14

Display precision.................................................................................................................................14

Right transducer..................................................................................................................................14

Line Tacho or Encoder * .....................................................................................................................14

Calibrate Tension ...............................................................................................................14

Calibration of the Total Tension Analog Output............................................................... 15

Calibrate Speed .................................................................................................................. 15

Product Parameters ........................................................................................................... 16

Controller Tuning ...............................................................................................................17

PI Stability Settings .............................................................................................................................17

Maximum Trim ....................................................................................................................................17

Soft Start............................................................................................................................. 17

Operating ............................................................................................................................ 18

Change Passwords ............................................................................................................ 18

Safety and EMC ..................................................................................................................18

AO-70174 2 Revision BA

Table Of Contents

Additional Information ....................................................................................................... 19

External tension set point input...........................................................................................................19

Tension set point output .....................................................................................................................19

Adjusting the screen contrast .............................................................................................................19

Troubleshooting .................................................................................................................19

Installation Record Sheet................................................................................................... 20

AO-70174 3 Revision BA

WebPro Intermediate Tension Controller

General Description

The WebPro Digital Tension Controller is part of a closed loop tension control system with transducer
feedback. The Controller continuously controls the web tension to the TENSION SET POINT value and
displays the true web tension on an LCD screen, either as a percentage or in engineering units. The
screen will display the tension applied to each transducer separately by pressing the < LEFT tension or >
RIGHT tension key. The sum of the LEFT and RIGHT tensions is displayed when the < > TOTAL key is
pressed. The Controller will control to the TOTAL tension value even when the LEFT or RIGHT tension is
being displayed. The Controller also has a dual range tension indication feature.

The measurement of actual web tension is made by sensing, with strain gauge transducers (sometimes
referred to as "load cells"), the force on a sensing roller caused by the tension in the web. The electrical
signal from the transducers is a combination of tension force and sensing roller weight. The weight of the
sensing roller is zeroed out electrically, leaving the tension force only to be displayed on the screen.
For wide web applications two transducers are recommended, one on each end of the sensing roller; for
narrow web, wire, cable and filaments one transducer can usually be used.

Intermediate Drive System

With the Controller in automatic mode the
measured tension is compared with the
desired tension. Any tension error is multiplied
by the incoming line speed making the
correction speed proportional. This multiplied
tension error is then conditioned by the PI
then added to the line speed signal and used
as a speed demand to the controlled ( slave )
drive. This is described in the Machine
Parameter menu as; Output Trim only - NO.

Alternatively the trim signal only may be
output as +/- 2V or as +/- 10V maximum. This
is described in the Machine Parameter menu
as; Output Trim only - YES. When this mode
is used the controlled drive will usually require
a line speed input in addition to the trim input.

The transducers and the controlled drive may be before the master drive or after, this is selected in the
Machine Parameter menu. Both the master drive and the controlled drive should be four quadrant
regenerative types to prevent overhauling.

All drive electronics MUST be isolated from any supply voltage and the electronics common (0V) should
be earthed. If the drive electronics are not isolated consult CMC Inc BEFORE use.

N

0

0

1

AO-70174 4 Revision BA

WebPro Intermediate Tension Controller

Quickstart

The Controller is supplied with the software loaded for the application as ordered but it will require
commissioning before use.

For more detailed information refer to the various sections later in this manual.

1. Carefully unpack the Controller, remove the rear cover and detach the bag containing the accessories.
Attach the cable gland to the large hole in the rear cover. Mount the Controller in the operators panel
using the two keyhole brackets provided.

2. Position the links LK1 to LK5 on the Printed Circuit Board correctly for the type of transducer used.

Ensure that the mains voltage selector is set correctly.

3. Thread the mains supply cable through the gland and connect to the orange two part connector.
Thread the transducer cables, machine interlock cables, output cable and any other cables through the
most convenient of the four smaller holes and connect to the terminal strips. If an encoder is to be used,
thread the encoder cable through the rear cover and connect to the header using the crimps provided.
Additional holes may be drilled and extra glands for the cables may be fitted by the user.

Ensure that the encoder is connected correctly to prevent damage to the power supply.

4. Fix the rear cover to the Controller and tighten the gland to retain the mains cable for safety purposes.

5. Switch on, the POWER LED will light, the company logos will be shown briefly then the Introduction

screen will be shown.

6. Press 4, Commissioning, enter the default password, by pressing 5678 then press the ENTER key.
Press 1, Machine parameters, then scroll through and enter the parameters for the installation.

By default only one transducer, the LEFT transducer, is enabled. For installations with two transducers,
which is the normal situation for web applications, the RIGHT transducer must be enabled.

If a tacho is used the MAXIMUM input voltage is +10V DC.

If an encoder is used the number of pulses per second at maximum machine speed must be entered.

To accept and save the Machine parameters the CONFIRM key MUST be pressed.

7. Calibration for the sensing roller weight and maximum tension to be used is required; calibration for the
speed of the machine may also be required.

8. The default Product number is 1 with a PI stability of SLOW. This should be sufficient to put the
machine into service. To change the stability, open the Adjust PI stability screen from the Commissioning
menu, start the machine and observe the bar graph. Reduce the PI stability to MEDIUM or FAST until the
bar graph fluctuations just start to increase, then press CONFIRM.

AO-70174 5 Revision BA

55

380

(

)

WebPro Intermediate Tension Controller

Installation

The following parts are supplied:-

1. Controller, with software loaded for the application but requiring commissioning by the user.

2. Two keyhole mounting brackets.

3. Cable gland to be fitted to the rear cover and header connector kit for encoders.

4. Cabinet, if ordered.

5. Manual (this document).
Transducers and cables may also be supplied to complete the system

The Controller should be installed using 'best practice' and in accordance with all relevant regulations.
The Controller must be installed in a dry, non-hazardous location. A panel cut out 8.27in (210mm) wide X

7.01in (178mm) high is required. The Controller is 3.94in (100mm) deep, additional space for the cables
is needed.

The Controller is retained by two mounting brackets. Remove the four screws securing the mounting
brackets to the Controller. Insert the Controller into the cut out in the panel. Refit the four screws, attach
the mounting brackets to the Controller and tighten the two nylon screws to retain the Controller.

Cabinet Installation

The cabinet has rear mounting holes for M8 fixing. When
the Controller is supplied as a cabinet version the mains

11.8 in

300mm

supply is terminated inside the cabinet on a three way
terminal block. The incoming mains cable should be
securely fastened by the gland plate cord grip.

PCB Link Positions

The links LK1 to LK5 MUST be in the proper positions for

1

6 in.

(155mm)

correct operation. It may be found more convenient to position the links before connecting the Controller.

LK1 Excitation Voltage Position B This gives 5.6V for Cleveland-Kidder transducers
LK1 Excitation Voltage Position A This gives 10V for ACDF and foil transducers
LK2 and LK3 IN For Cleveland-Kidder transducers to complete the bridge
LK2 and LK3 OUT For full bridge transducers, the bridges are complete
LK4 and LK5 Gain Position A Normal gain for Cleveland-Kidder transducers
LK4 and LK5 Gain Position B High gain for Cleveland-Kidder transducers
LK4 and LK5 Gain Position C Normal gain for ACDF and foil transducers
LK4 and LK5 Gain Position D High gain for ACDF and foil transducers

The high gain positions providing three times the normal gain are used if the transducers are oversized
and there is insufficient signal level for accurate calibration.

LEN 312 541

TB1

TB2

TB5

2 in. (50mm)

CUT OUT

8.27 in. x 7.01 in.

210 X 178

(210x178mm)

ENTRY GLAND PLATE

10965423 87131211

15 in.

(380mm)

LOCK

1

TB3

HD2 HD1

6 16 1

AO-70174 6 Revision BA

3245687 9 10 1411 12 13 15

132 456

TB4

LK2

LK3

LK4

A
B
C
D D

LK1LK5

A
B
C

AB

VR2 SPAN

VR1 ZERO