A30 Single Range Tensioncells
P-2012-3
819-0403
Installation Instructions
Contents
General Information . . . . . . . . . . . . . . . . . . . 3
Installation and Operation . . . . . . . . . . . . . . . 6
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 9
Recalibration . . . . . . . . . . . . . . . . . . . . . . . 10
Dimension Drawing . . . . . . . . . . . . . . . . . . 11
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
2
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
Warner Electric • 800-825-9050 P-2012-3
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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.
Warner Electric • 800-825-9050 P-2012-3
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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
Warner Electric • 800-825-9050 P-2012-3
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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
Warner Electric • 800-825-9050 P-2012-3
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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
Warner Electric • 800-825-9050 P-2012-3
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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 notied 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 specic legal
rights and you may also have other rights which vary from state to state.
Changes in Dimensions and Specifications
All dimensions and specications shown in Warner Electric catalogs are subject to change without
notice. Weights do not include weight of boxing for shipment. Certied 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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