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Cleveland Motion Controls
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MWP-12664
User Manual
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Table of contents
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Cleveland Motion Controls MWP-12664 User Manual

WINDER TENSION CONTROLLER
MWP - 12664
Instruction Manual
AO-70171 (Rev BA)
B l a n k

Table Of Contents

General Description .............................................................................................................4
Winder Control Systems .......................................................................................................................4
Quickstart ............................................................................................................................. 5
Installation ............................................................................................................................ 6
Cabinet Installation ...............................................................................................................................6
PCB Link Positions ..............................................................................................................6
Controller Connections........................................................................................................ 6
Controller Connections........................................................................................................ 7
Connections for Clutch Winder Using an E/P Converter or High Current Driver............. 7
Connections for Speed Control........................................................................................... 8
Connections for Torque Control ......................................................................................... 8
Connections for Surface Winder......................................................................................... 8
Transducer Connections ..................................................................................................... 9
Intrinsically Safe Transducer Connections for Hazardous Area Installations.......................................9
Machine Sequence Logic and Connections .......................................................................................10
Digital Output Connections .................................................................................................................10
Power Supply Connections.................................................................................................................11
Tacho Connections .............................................................................................................................11
Encoder Connections..........................................................................................................................11
Length Counter ...................................................................................................................................11
Batch Hold ..........................................................................................................................................11
System Set Up .................................................................................................................... 12
Machine Parameters........................................................................................................... 13
Language ............................................................................................................................................14
Unit system .........................................................................................................................................14
Winder type .........................................................................................................................................14
Output range .......................................................................................................................................14
Start in control screen .........................................................................................................................14
Enable MAN / AUTO / OFF keys........................................................................................................14
Dual tension range ..............................................................................................................................14
Minimum tension .................................................................................................................................14
Static friction .......................................................................................................................................15
Dynamic friction ..................................................................................................................................15
Output level bias .................................................................................................................................15
Output level limit .................................................................................................................................15
Diameter adjustment ...........................................................................................................................15
Set point ramp rate .............................................................................................................................15
Soft stop time ......................................................................................................................................15
Display damping time..........................................................................................................................15
Display precision.................................................................................................................................15
Right transducer..................................................................................................................................15
Line Tacho or Encoder * .....................................................................................................................16
Winder Tacho or Encoder * ................................................................................................................16
Calibrate Tension ...............................................................................................................16
Calibration of the Total Tension Analog Output............................................................... 17
Calibrate Speed .................................................................................................................. 17
Table Of Contents
Product Parameters ........................................................................................................... 18
Controller Tuning - Speed Control .................................................................................... 18
Output Level Bias................................................................................................................................18
Output Level Limit ...............................................................................................................................18
PI Stability Settings .............................................................................................................................18
Maximum Trim ....................................................................................................................................19
Controller Tuning - Torque Control................................................................................... 19
Output Level Limit ...............................................................................................................................19
Static Friction ......................................................................................................................................19
Dynamic Friction .................................................................................................................................19
PI Stability Settings .............................................................................................................................20
Maximum Trim ....................................................................................................................................20
Inertia Compensation ..........................................................................................................................20
Controller Tuning - Surface Winder .................................................................................. 20
Output Level Limit ...............................................................................................................................21
Output Level Bias................................................................................................................................21
PI Stability Settings .............................................................................................................................21
Maximum Trim ....................................................................................................................................21
Controller Tuning - Clutch Winder .................................................................................... 22
Output Level Bias................................................................................................................................22
Output Level Limit ...............................................................................................................................22
PI Stability Settings .............................................................................................................................22
Soft Start and Soft Stop Time............................................................................................ 22
Operating ............................................................................................................................ 23
Change Passwords ............................................................................................................ 23
Safety and EMC ..................................................................................................................23
Additional Information ....................................................................................................... 24
External tension set point input...........................................................................................................24
Tension set point output .....................................................................................................................24
Adjusting the screen contrast .............................................................................................................24
Diameter calculation ...........................................................................................................................24
Troubleshooting .................................................................................................................24
Installation Record Sheet................................................................................................... 25
WebPro Winder 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.

Winder Control Systems

The Winder Controller is designed for four application areas;
• surface winder in speed trim control,
• clutch winder,
• center winder in speed control,
• center winder in torque control,
both center winders have a taper feature.
All drive electronics MUST be isolated from any supply voltage and the electronics common (0V) should be grounded. If the drive electronics are not isolated consult CMC Inc BEFORE use.
N
0
0
1
A motor driven center winder with taper feature
N
0
0
1
N
0
0
1
A surface winder
A clutch winder
WebPro Winder 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.
155
380
(
)
WebPro Winder 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 specifications. The Controller must be installed in a dry, non-hazardous location. A panel cutout 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
11.8 in
300mm
mains 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
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
1
TB3
132456
3245687 9 10 1411 12 13 15
10965423 87131211
TB5
TB4
2 in. (50mm)
CUT OUT
8.27 in. x 7.01 in.
210 X 178
(210x178mm)
ENTRY GLAND PLATE
15 in.
(380mm)
LOCK
LK2
LK3
LK4
HD2 HD1
6 16 1
LK5
A B C D D
LK1
A B C
AB
VR2 SPAN
VR1 ZERO
WebPro Winder Tension Controller

Controller Connections

WARNING - Disconnect the Controller completely before any electric welding is undertaken on the
machine. Failure to carry out this precaution could damage the Controller and will invalidate the warranty.
WARNING - The PCB uses devices sensitive to electrostatic voltages. Do NOT touch any components without first using proper electrostatic discharge ESD precautions.
The Controller uses Wago Cage Clamp terminals, it is recommended that the correct tool is used when inserting the cables. Wago part number 210-120 is available from Wago or CMC Inc. Do NOT strain the terminals or the PCB. The terminals are suitable for cable sizes 12-24 AWG, 0.1-
2.5sqmm. The cable ends should be terminated with ferrules or crimp tags.
It is necessary to remove the rear cover to connect the Controller, set the links and select the mains supply voltage. Remove the rear cover and fit the cable gland (supplied loose) to the rear cover. Feed the mains cable through the cable gland and connect to the two part connect as shown. Feed the transducer cables and other cables through the most convenient holes in the rear cover and connect to the terminals. Replace the rear cover and secure the cable gland to retain the mains cable for safety purposes.
All the Controller 0V commons, analog and digital, are connected to earth E and to the metal case.
TB4 – Analog I/O TB5 – Digital I/O

Connections for Clutch Winder Using an E/P Converter or High Current Driver

IN
Fairchild TA6000-
406
Fairchild TA6000-406 connections for 4-20mA input
Fairchild TT6000-
006
Fairchild TT6000-006 connections for 0-10V input
High Current Driver connections for 0-10V input
COM
OUT-
OUT+
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