Warner Electric A30 User Manual

A30 Single Range Tensioncells
P-2012-3 819-0403
Installation Instructions
Contents
General Information . . . . . . . . . . . . . . . . . . . 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recalibration . . . . . . . . . . . . . . . . . . . . . . . 10
Warranty . . . . . . . . . . . . . . . . . . . . . Back Page
Failure to follow these instructions may result in product damage, equipment damage, and serious or fatal injury to personnel.
Warner Electric • 800-825-9050 P-2012-3
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Description
Damper
C-Flexure Far Side
Mechanical Stop
Load Plate
LVDT LVDT
Core
A. General Information
Warner Electric Series 30 Type A Tensioncells are force transducers, specially designed to measure and control tension on single strand wire, cable or filaments, on continuous strip pro­cessing lines. They convert the mechanical force of strand tension into an electrical signal, which is directly proportional to the strand ten­sion.
Type "A" Tensioncells are installed as single units with a pulley or sheave (See Figures 1a and Figure 1b). They are intended for NON­ROTATING shaft installations. Tensioncells can be provided to accept shaft sizes from 3/4 inch to 1-7/16 inch. (See Table 1-B, Page 11)
B. The Mechanical System
The mechanical system consists of a Patented "C-Flexure Pivot Assembly" which incorporates a mounting Base Block, frictionless elastic pivot (or hinge), and Load Plate. (See Figure 2) When a mechanical force is applied to the Load Plate, the pivot permits its deflection toward or away from the Base Block.
For our discussion here, deflection of the Load Plate toward the Base Block is defined as the "Compression Mode", while the opposite is defined as the "Tension Mode". Tensioncells are designed to operate equally well in either mode.
The Base Block contains an integral Mechanical Stop to limit the amount of deflection in either direction, and a Viscous Damper to allow control of the tensioncell response to rapid changes in apparent tension loads. (See Figure 2)
W1
Figure 1a Figure 1b
W1
Figure 2
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C. The Electrical System
Black - (2) Red + (1)
Green (3) Blue (4)
Input
Output
X Twisted Leads
A B
Oscillator Demodulator
P1
S1
S2
X
X
WhenSupplied
withCable
(1)Red +DC (2)Black –DC
(3)Green –Signal (4)White +Signal
CD
BAC
D
7
6
5
4
3
2
1
0
.030” 0.0 .030”
3.5 V. Set Point
Tension
Compression
LVDT Output vs Deflection
O
u
t p u
t
V
o
l
t a g e
Deflection
The electrical system consists of a Linear Variable Differential Transformer (LVDT) which converts the mechanical deflection of the Load Plate into a useful electrical output signal. (See Figure 3) The moveable core of the LVDT is mechanically coupled to the Load Plate. This core assemble is factory set and is not accessible.
D. Type "K" DC LVDT
As illustrated in Figure 3, a DC LVDT consists of the following components:
An oscillator network, which converts the DC input voltage into a high frequency alternat­ing current for exciting the primary coil (P1)
A Primary Coil (P1)
A movable, permeable metallic core
Two Secondary Coils (S1 and S2)
A demodulator and summing network to rec­tify and integrate the currents from the Secondary Coils
With Warner Electric LVDTs, the input and out­p
ut circuits are electrically isolated from each other and from the mechanical structure of the tensioncell. Thus, they may be used in "floating ground" or "ground return" systems. This elimi­nates the need for extra circuit boards which are required for most straingage loadcells.
Tensioncells are factory adjusted to provide an offset voltage with no load applied (no deflec­tion). Using an input of 24 volts DC, the LVDT is set to provide an output of 3.5 volts into a resis­tive load of not less than 100,000 ohms. The voltage resulting from the maximum rated deflection then adds to or subtracts from the 3.5 volt offset. This results in an output voltage of
3.5 to 6.5 volts in the Compression Mode and
3.5 to 0.5 volts in the Tension Mode. (See Figure 4)
While acceptable performance may be obtained over an input voltage range of 6.0 to 30.0 volts DC, the output voltage will vary in direct propor­tion to the input voltage. Because of this, the use of a well regulated constant voltage power supply is essential for accurate and repeatable tension measurement.
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Figure 3
LVDT Output vs. Deflection Chart
Figure 4
E. Description of Operation
Nominal
L
R
E
D
H
E
RF
N
TW
T
T
T
he total resultant load per cell (RF) is calculat­ed by resolving all force vectors acting upon the Tensioncell, with respect to the Loading Line (OL). (RF) is the resultant of both TENSION and TARE loads, PER CELL!! (See Figure 5)
The intrinsic design of Warner Electric Tensioncells allows the location of the Resultant Load of Strip Tension (H) on any angle with respect to the Load Line (OL). Note, however, that the Total Force vector (RF) must always be calculated on the line (OL).
Any force vector falling on the line (OR) (through the pivot point of the C-Flexure) will produce no deflection, and thus no electrical output.
Rotating the Tensioncell on its mounting bolt changes the force vectors on the cell. This fea­ture makes it possible to minimize the tare com­ponent and maximize the load signal output.
T
he resultant tare is minimized by mounting the
Tensioncell so that (N) is 31°. (See Figure 6)
Figure 5
Figure 6
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Installation and Operation
1.63
1.06
.25 Dia.
5/8-11 UNC
1.06
W1
W2
A. Inspection Upon Delivery
Warner Electric tensioncells are carefully pack­aged in sturdy reinforced cartons or wooden boxes and are securely blocked or bolted in place.
1. Upon receipt, examine the exterior of the con-
tainer for obvious damage or tampering.
2. Check the contents against the packing list.
3. Promptly report any damage or shortage to
both the carrier and Warner Electric.
B. Handling
Tensioncells can be handled manually.
C. Long Term Storage
While Warner Electric loadcells are plated, expo­sure to weather, dirt, or moisture should be avoid­ed when they are stored.
The locating tab prevents the Tensioncell from r
otating and secures it in a permanent location. It also provides a means of repeating rotary position when the Tensioncell needs replace­ment.
Note: Remove the 1/4" locking screw and the 5/8" mounting bolt. This permits the roll assembly with Tensioncells to be lifted out of the machine.
D. Mechanical Installation
Note: Refer to the Dimension Drawing Pages
10 and 11 of this manual for detailed identification of all parts.
Tensioncells are designated as W1 and W2, one being the mirror image of the other. (See Figure 7)
Warner Electric Wall Mounted Tensioncells are mounted to the machine frame by a 5/8-11 UNC bolt which is in line with the centerline of the measuring roll shaft. This allows the Tensioncell to be r
otated around the centers of the measuring roll and mounting bolt to achieve the proper mounting angle. (Description of Operation on Page 5)
Figure 7
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To install Tensioncells:
Black - (2) Red + (1)
Green (3) Blue (4)
Input
Output
X Twisted Leads
A B
Oscillator Demodulator
P1
S1
S2
X
X
When Supplied
with Cable
(1) Red + DC (2) Black – DC
(3) Green – Signal (4) White + Signal
C D
BAC
D
1. Make sure a 5/8” diameter hole is drilled
through the machine frame in line with the centerline of the measuring roll shaft for the 5/8-11 UNC mounting bolt.
E. Mechanical Alignment
Align the sectional measuring roll to avoid any mechanical binding or friction. The measuring roll must be level and perpendicular to the path of the strip material for accurate measurement.
2. Fasten the Tensioncell to the machine frame
with the mounting bolt.
3. Rotate the Tensioncell to the proper mount-
ing angle and tighten the mounting bolt. (Refer to Y on the calibration sheet for the proper mounting angle.)
4. Drill a #6 (.204) hole concentric with the 1/4"
hole in the locating tab.
5. Remove the Tensioncell and tap the hole for
a 1/4-20 thread.
6. Assemble the Tensioncells onto the ends of
the measuring roll shaft.
7. Position the roll with the Tensioncells on the
machine and fasten with the mounting bolts.
8. Rotate the Tensioncells to the proper mount-
ing angle and tighten the mounting bolts.
The Mechanical Stops are fixed for the required travel of the Load Table.
F. Electrical Installation
(Read the entire electrical wiring procedure before proceeding.)
1. Turn off all electrical power to the loadcell.
2. Use twisted four conductor signal cable, Belden 9402 or equivalent, in grounded steel conduit from the LVDTs to the control panel.
3. Observing correct polarity, connect the posi­tive (+) input lead to Pin A and the negative (-) input lead to Pin B. (See Figure 8)
4. Connect the positive (+) output lead to Pin D and the negative (-) output lead to Pin C. (See Figure 8)
9. Lock the locating pad for each Tensioncell against the machine frame using the 1/4-20 x 1/2 socket head cap screw.
10. Tighten the shaft in the mounting block on the W1 unit.
Figure 8
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Set up and Adjustments Specifications
Roll
Rope
Web Path
Weights for
Max. Tension
Type "K" 24 volt DC LVDT Specifications
Input . . . . . . . . . . . . . . . . . . . . . . . . .6-30 volts DC
Output . . .0.5-6.5 volts DC (nominal, open circuit)
Output Impedence . . . . . . . . . . . . . . . .2.5K ohms
Current Consumption . . . . . . . . . . . . . . . . . .40 mA
Recommended Load . . . . . .100K ohms or greater
Max. Operating Temp . . . . . . . . . . . . . . . . . .250°F
Note: Warner Electric loadcells are calibrated for 24 volt DC input voltage to provide a 0.5 to 6.5 volts DC output signal.
Full Load Adjustment
After the loadcell has been zeroed, a pull test can be made to check the output voltage of the loadcell at full load.
1. Run a non-stretchable rope over the center of the tension roll simulating the web path. (
Note: The rolls should be free to turn.)
2. With one end of the rope secured, hang a known weight equally over the roll so that the total tension is equal to the maximum strip tension specified on the calibration sheet, at the other end. (See Figure 9)
Electrical Zero Adjustment
(Read the complete Electrical Zero Adjustment procedure before proceeding with the adjust­ment.)
1. Disengage strip from the measuring roll so that no tension force is applied to the load­cell.
2. Connect a voltmeter to Pins C and D. (See Figure 8)
3. Apply 24 volt DC electrical power to the loadcell observing the correct polarity. [Plus (+) to Pin A and minus (-) to Pin B.] Do not exceed the maximum rated input voltage.
Note: Allow 20 minutes for the loadcell to warmup before taking first readings to insure accurate readings.
3. With a voltmeter connected to Pins C and D of the connector, an output voltage will be observed.
Warner Electric Ioadcells instrumentation pro­vides the required signal conditioning and a reli­able high level output signal for use as feedback control of a tension drive system. The feedback signal is directly proportional to the strip tension applied. If a Warner Electric control is used, refer to the control manual for further calibration.
Although the electrical output of Warner Electric tensioncells are sufficient to drive most electrical indicators, substantial signal conditioning is nor­mally required for effective tension instrumenta­tion system control. Refer to the documentation available from the instrumentation supplier for more information.
4. Measure the output voltage of the LVDT between the Green and Blue leads for each tensioncell with a volt meter with a sensitivity of at least 100,000 ohms per volt. The out­put voltage should be between 0.5 and 6.5 volts.
5. Since Warner Electric Tensioncells cannot be mechanically zeroed, refer to the Control Manual for zeroing out the tare weight volt-
Warner Electric • 800-825-9050 P-2012-3
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(Figure 9)
Trouble Shooting
Black - (2) Red + (1)
Green (3) Blue (4)
Input
Output
X Twisted Leads
A B
Oscillator Demodulator
P1
S1
S2
X
X
When Supplied
with Cable
(1) Red + DC (2) Black – DC
(3) Green – Signal (4) White + Signal
C D
BAC
D
3. Are LVDTs open or shorted?
When properly installed in accordance with the original design specifications Warner Electric tensioncells should require little or no regular maintenance or service.
Certain conditions, however, can impair their inherently accurate and reliable performance. Therefore, if trouble should arise, the following conditions should be checked.
1. Has the tension measuring system been changed?
a. An increase or decrease in strip tension. b. An increase or decrease in the wrap
angle. If the above parameters have been
changed enough to prevent the unit from operating within the limits of the fixed Mechanical Stop, restore parameters to previous condition or consult factory.
2. Is the loadcell mounted securely?
To check, tur n off power and disconnect the input and output leads. Check coil continuity and resistance. (Refer to Figure 10)
Figure 10
a Pin A to Pin B (Primary Coil) should be in
excess of 2 megohms.
3. Is tension measuring roll in proper alignment and does it turn freely?
4. Are bearings and seals free of all binding and stickiness? Are they worn?
Electrical
1. Are LVDTs receiving correct input voltage? Check line voltage, fuses or circuit breakers,
and power switches. Check power supply output and voltage to LVDTs.
2. Are all connections secure? Check for continuity. Retighten all connec-
tions. Recheck operation.
b. Pin A or Pin B to LVDT shell should be in
excess of 5 megohms.
c. Pin C to Pin D (Secondary Coil) should
be approximately 20,000 ohms.
d. Pin C or Pin D to LVDT shell should be in
excess of 5 megohms.
If LVDT circuits are open or shorted, replace LVDT. Contact Warner Electric with tensioncell model number and serial number.
Warner Electric • 800-825-9050 P-2012-3
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Recalibration After Installation
Wall Mounted Tensioncells can be relocated around the center of the measuring roll. The the­ory of this operation is explained in the Description of Operation on Page 5. If this pro­cedure cannot accomplish the necessary changes because the tension requirements are extremely different than the original application, it will be necessary to return the Tensioncells to the factory for new cells.
Model Number Nomenclature Example
Electrical Connection
B - MS Connector
Type
A - Pulley or Sheave
Note: For dual load cell applications “W1” and “W2” cell are requir ed.
Series Number (2 Digits)
30 Wall Mount
B A 3 0 T 1 6 K W1
Capacity Range
See T
able 1-A
K - DC LVDT with Maximum 3 VDC Output Change Including Tare Displacement
Shaft Diameter
See Table I-B for Type A
Series 30, Type A Specifications – Non-Rotating Shaft Mounting
Series 30, Type A – Nominal Capacity Ranges
Code P T U
Pounds 0-20 0-50 0-90
Example Shown:
BA30T16KW1
B = MS Connector A = Pulley Mount 30 = Series 30, Wall Mount T = 0-50 lbs. Capacity 16 = 1” Diameter Shaft K = K Type DC LVDT W = Split Bushing
Shaft Mounting
Configuration
W1 Split bushing W2 Solid bushing
Table I-A
Note: Other load ratings are available as special order. Contact Warner Electric for other load ranges available.
Warner Electric • 800-825-9050 P-2012-3
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2.44
1.56
.94
3.31
1.63
1.06
1.81
3.42
4-Pin Connector
3.63
3
.75
2.63
5/8 - 11UNC**
.25 Dia. Hole for Locking Screw
2.31
1.00
3.56
** Warner Electric wall mounted tensioncells are located by a 5/8-11 bolt at the roll centerline
and locating tab which maintains rotational position to the tensioncell. (See Page 5.)
Shaft Specifications
Code Inches 12 16 20
3/4 1.0 1-1/4
Table I-B
Note: Other shaft diameters ar or
der. Contact Warner Electric for other shaft
e available as special
diameter availiblilty.
Warner Electric • 800-825-9050 P-2012-3
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Warranty
Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any product manufactured and sold by it which proves to be defective in material or workmanship within a period of one (1) year from the date of original purchase for consumer, commercial or industrial use.
This warranty extends only to the original purchaser and is not transferable or assignable without Warner Electric LLC’s prior consent.
Warranty service can be obtained in the U.S.A. by returning any defective product, transportation charges prepaid, to the appropriate Warner Electric LLC factory. Additional warranty information may be obtained by writing the Customer Satisfaction Department, Warner Electric LLC, 449 Gardner Street, South Beloit, Illinois 61080, or by calling 815-389-3771.
A purchase receipt or other proof of original purchase will be required before warranty service is rendered. If found defective under the terms of this warranty, repair or replacement will be made, without charge, together with a refund for transportation costs. If found not to be defective, you will be notied and, with your consent, the item will be repaired or replaced and returned to you at your expense.
This warranty covers normal use and does not cover damage or defect which results from alteration, accident, neglect, or improper installation, operation, or maintenance.
Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply to you.
Warner Electric LLC’s obligation under this warranty is limited to the
repair or replacement of the defective product and in no event shall Warner Electric LLC be liable for consequential, indirect, or incidental damages of any kind incurred by reason of the manufacture, sale or use of any defective product. Warner Electric LLC neither assumes nor authorizes any other person to give any other warranty or to assume any other obligation or liability on its behalf.
WITH RESPECT TO CONSUMER USE OF THE PRODUCT, ANY IMPLIED WARRANTIES WHICH THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL CONSUMER PURCHASE. WITH RESPECT TO COMMERCIAL AND INDUSTRIAL USES OF THE PRODUCT, THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specic legal rights and you may also have other rights which vary from state to state.
Changes in Dimensions and Specifications
All dimensions and specications shown in Warner Electric catalogs are subject to change without notice. Weights do not include weight of boxing for shipment. Certied prints will be furnished without charge on request to Warner Electric.
Warner Electric LLC
31 Industrial Park Road • New Hartford, CT 06057 815-389-3771 • Fax: 815-389-2582 www.warnerelectric.com
P-2012-3 819-0403 7/05 Printed in USA
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