Warner Electric AC10 User Manual

AC10 Measuring System

P-2012-2
819-0402

Installation Instructions

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

System Overview. . . . . . . . . . . . . . . . . . . . . . . 3

AC10 Tensioncells . . . . . . . . . . . . . . . . . . . . . . 4

AC10 Electronics . . . . . . . . . . . . . . . . . . . . . . . 5

AC10 Specifications . . . . . . . . . . . . . . . . . . . . 6

Pushbutton Key Functions . . . . . . . . . . . . . . . 7

Installation

Pre-Installation Inspection. . . . . . . . . . . . . . . . 8

Mechanical Installation . . . . . . . . . . . . . . . . . . 8

Electrical Installation . . . . . . . . . . . . . . . . . . . 10

Electrical Connections. . . . . . . . . . . . . . . . . . 10

Initial Electrical Checks . . . . . . . . . . . . . . . . . 12

AC10 Setup Procedure . . . . . . . . . . . . . . . . . 13

Programmable Threshold Relay . . . . . . . . . . 15

Reset Tare to Zero . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 16

Failure to follow these instruc­tions may result in product damage, equip­ment damage, and serious or fatal injury to
personnel.

Introduction

This manual is intended for use by qualified per­sonnel to assist them in the safe setup and
operation of the Warner Electric AC10 Tension
Measuring System. Warner Electric has made
every effort to insure the accuracy and com­pleteness of the information and recommends
that all procedures be read and understood
before performing them. Please contact Warner
Electric with any questions regarding any infor­mation contained in this manual.

Dimension Drawings

AC10 Tensioncells . . . . . . . . . . . . . . . . . . . . . 18

Model Number Designation. . . . . . . . . . . . . . 18

PSAC10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Warranty . . . . . . . . . . . . . . . . . . . . . Back Page

Warner Electric • 800-825-9050 P-2012-2

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System Overview

J

3

J4

J6

J5

W

arner
Part# 80-165 Rev
Serial#

Setup

Rapid

E

xit

Setup

E

nter

J7

J8

J9

J

1

J2

PSAC10 Board

Power
Switch

Output #1

Output #2

Control

Analog or Digital

Meter

Drive

Cell #1/Total/Cell #2

Switch

AC-10 Tensioncells

Threshold
Alarm

RS-422
Interface

MCS2000-CTDA

MCS2000-CTDA

Control

Analog or Digital

Meter

Drive

The AC10 Tension Measuring System is designed
to measure tension on continuous strip process­ing lines and equipment. The system consists of
two AC10 Tensioncells, the PSAC10 power supply
amplifier board, and two cables for connecting the
Tensioncells to the board.

AC10 Tensioncells are mounted in pairs, one at
each end of the measuring roll. During operation
the Tensioncells continuously measure the
mechanical tension force applied to the measuring
roll. When the force is applied, the load plate
deflects toward or away from the base block
depending on the resultant force acting upon the
Tensioncell. Deflection toward the base block is
defined as the "Compression Mode.” Deflection
away from the base block is defined as the
"Tension Mode." AC10 Tensioncells work equally
well in either mode.

The mechanical deflection of the load plate is
converted into an electrical output signal by the

AC Linear Variable Differential Transformer
(LVDT). Displacement of the LVDT core caused
by variations in web tension results in an output
signal to the PSAC10 board directly proportional
to the applied tension.

The analog outputs from the Tensioncells are con­verted into digital signals by the microprocessor­based electronics. The signals are conditioned,
processed, and summed to produce two individu­ally scaleable, -10 to +10 volt DC analog outputs
to a tension indicator, drive or a MCS2000 CTDA
control which can be used to monitor or control
tension. The percent tension applied to each
Tensioncell and the total tension are displayed on
the board mounted 16-character liquid crystal
display (LCD).

Terminals are also provided for connecting a user
supplied On/Off power switch, 1-only 2-only
switch, and RS-422 PC interface. A threshold
alarm relay connection is also provided.

Note: When using the PSAC10 board, connect the outputs to the MCS2000 CTDA. There is no
need to use the MCS2000 CTLC, because the signal is amplified and summed in the PSAC10.

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AC10 Tensioncells

Shaft Support
Block

Self-Aligning
Shaft Support
Bushing

Electrical
Connector

5/8-1 1 UNC

Mounting

Hole

Load Plate

C-Flexure

Mechanical Stop

LVDT

LVDT Core

Base Block

Locating Tab

AC10 Tensioncells are available in three capaci­ty ranges for non-rotating shaft applications
with maximum resultant force plus tare load of
60, 170, or 500 pounds respectively.

The rugged, all-steel construction of the AC10
Tensioncell includes four basic components: the
one-piece base block, the patented C-Flexure,
the load plate, and the shaft support block. The
factory-set mechanical stop provides overload
protection up to ten times the maximum rated
load capacity of the unit.

Each unit is wall mounted by means of a single
bolt located in line with the integral self-aligning,
stainless steel shaft support bushing and the

centerline of the roll shaft. This permits the
Tensioncell to be rotated and mounted at the
required angle around the axis of the measuring
roll. The locating tab at the bottom of the unit
locks it in position.

The primary conversion element between the
mechanical tension force and the electrical out­put signal is an AC Linear Variable Differential
Transformer (LVDT). The LVDT electrical ele­ments are encapsulated and sealed against
shock, vibration, or tampering. Input and output
circuits are isolated from each other and from
the Tensioncell body. This permits the
Tensioncells to be used in floating ground elec­trical systems.

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AC10 Electronics

J3

J4

J6

J5

Warner
Part# PSAC10
Serial#

Setup

Rapid

Exit

Setup

Enter

J7

J8

J9

J1

J2

Input Power
Selector Switch

Input Power
Terminal

Power On
Switch Terminal

Output #1
Output #2
Terminal

Cell #1/T otal/Cell#2
Switch Terminal

Tensioncell #1
Terminal

Tensioncell #2
Terminal

16-Character LCD

LCD Brightness
Adjustment

Pushbutton Keys

Threshold Relay
Terminal

RS-422 Output
Terminal

Run Mode LED

Spare

230V

The AC10 microprocessor-based electronics
adds ease of setup, versatility, and accuracy of
the overall system by eliminating the need for
potentiometers to adjust or setup the system.
All adjustments and system settings are per­formed by using the pushbutton keys on the
board. During setup, alphanumeric prompts are
displayed on the 16-character LCD to guide the
user through the setup procedure.

Other features of the PSAC10 board include:

Two individually scaleable -10 to +10 volt DC
outputs
Run Mode LED

Programmable threshold relay
Cell#1/Total/Cell#2 switch connection
LCD Brightness Adjustment
Switch selectable 115/230 volt AC input
power

An RS422 Serial Output terminal is also provid­ed for interfacing the AC10 system with a PC to
monitor and/or record the percent tension
applied to each Tensioncell. Data is transferred
in ASCII text format. The RS422 output can be
converted to RS-232.

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Specifications

AC10 Tensioncells

Dimensions (I x w x h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.00" x 3.44" x 3.90"

Maximum Load Capacity (tension plus tare)

AC10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 pounds

AC10B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170 pounds

AC10C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 pounds

Minimum Tension Load Required for Setup

AC10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 pounds

AC10B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 pounds

AC10C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 pounds

Standard Shaft Diameters (1/16" increments) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1/2" to 1-1/2"

Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 times maximum rated load of unit

Maximum Deflection at Full Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.010"

LVDT

Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250°F maximum

Excitation Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Vrms @5KHz

Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 volts AC/inch displacement / volt excitation

Excitation Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335 Ohms ±5%

Output Signal Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Ohms ±5%

Linearity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.1% of full scale

Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.1% of full scale

Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.1% of full scale

Temperature Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.02% per °C

PSAC10 Power Supply/Amplifier Board

Dimension (I x w) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.75" x 6.88"

Maximum height of components above board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5"

Operating Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32°F to +160°F (0°C to +70°C)

Input Voltage (switch selectable) . . . . . . . . . . . . . . . . . . . . . . . . . .115/230 VAC, 50-60 Hz, <1.0 Ampere

Output Voltage (two individually scaleable)

Maximum cable distance between Tensioncell and board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 feet

(The output load to the board must be 2 kΩ or greater)

Threshold Relay Contact . . . . . . . . . . . . . . . . . . .1A @ 24 VDC, 500mA@ 120 VAC, 250 mA @ 220 VAC

RS-422 Data Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300bps, NP, 8, 1 stop bit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-10 to +10 VDC

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