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FM Series
User Manual
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Warner Electric FM Series User Manual

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FM Series Foot Mounted Load Cells
AC10 Measuring System A30 Single Range Tensioncells B30 Single Range Tensioncells
C30 Single Range tensioncells
P-2012
Installation Instructions
Contents
FM Series Foot Mounted Load Cells. . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . 4
Wiring Hookup . . . . . . . . . . . . . . . . . . . . . . 5
System Example. . . . . . . . . . . . . . . . . . . . . 5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 6
AC10 Measuring System. . . . . . . . . . . . . . . . . 7
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . 8
System Overview . . . . . . . . . . . . . . . . . . . . 9
AC10 Tensioncells. . . . . . . . . . . . . . . . . . . 10
AC10 Electronics . . . . . . . . . . . . . . . . . . . 11
AC10 Specifciations . . . . . . . . . . . . . . . . . 12
Installation. . . . . . . . . . . . . . . . . . . . . . . . . 14
Pre-Installation . . . . . . . . . . . . . . . . . . . . . 14
Mechanical Installation . . . . . . . . . . . . . . . 14
Electrical Installation. . . . . . . . . . . . . . . . . 16
Electrical Connections . . . . . . . . . . . . . . . 16
Initial Electrical Checks. . . . . . . . . . . . . . . 18
AC10 Set up Procedure . . . . . . . . . . . . . . 19
Programmable Treshold Relay . . . . . . . . . 21
Reset Tare to Zero . . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . 22
Dimension Drawings. . . . . . . . . . . . . . . . . 24
AC10 Tensioncells. . . . . . . . . . . . . . . . . . . 24
Model Number Designation . . . . . . . . . . . 24
PSAC10. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
C30 Single Range Tensioncells . . . . . . . . . . . 49
General Information . . . . . . . . . . . . . . . . . 50
Installation and Operation. . . . . . . . . . . . . 54
Adjustments . . . . . . . . . . . . . . . . . . . . . . . 56
Troubleshooting . . . . . . . . . . . . . . . . . . . . 56
Recalibration. . . . . . . . . . . . . . . . . . . . . . . 57
Dimension Drawing. . . . . . . . . . . . . . . . . . 59
Warranty. . . . . . . . . . . . . . . . . . . . . . Back Page
Failure to follow these instruc­tions may result in product damage, equip­ment damage, and serious or fatal injury to personnel.
A30 Single Range Tensioncells . . . . . . . . . . . 27
General Information . . . . . . . . . . . . . . . . . 28
Installation and Operation. . . . . . . . . . . . . 31
Adjustments . . . . . . . . . . . . . . . . . . . . . . . 33
Troubleshooting . . . . . . . . . . . . . . . . . . . . 34
Recalibration. . . . . . . . . . . . . . . . . . . . . . . 35
Dimension Drawing. . . . . . . . . . . . . . . . . . 36
B30 Single Range Tensioncells . . . . . . . . . . . 37
General Information . . . . . . . . . . . . . . . . . 38
Installation and Operation. . . . . . . . . . . . . 42
Adjustments . . . . . . . . . . . . . . . . . . . . . . . 43
Troubleshooting . . . . . . . . . . . . . . . . . . . . 44
Recalibration. . . . . . . . . . . . . . . . . . . . . . . 45
Dimension Drawing. . . . . . . . . . . . . . . . . . 47
2
P-2012-1 819-0401
FM Series Foot Mounted Load Cells
Warner Electric • 800-825-9050 P-2012-1
3
The FM style load cell provides easy and conven-
Zero setting: Green LED ON above 0 VDC
Gain setting: Green LED ON below 5 VDC
Green LED D-Sub connector
ient mounting to the roll that is being measured (used with pillow blocks). The load cell is a strain gauge style unit that is ideal for heavy tension applications. It can be mounted regardless of ori­entation, but has to work in compression. Only the perpendicular force (resultant) is measured by the load cell. The perpendicular force can be at a maximum permitted angle of +/- 30 degrees. Correct load cell sizing must be adhered to so potential overload forces do not damage cells.
FM Series Part Numbers
F M 0 1 - 1 0 0 0 - A C
Specifications:
Load Ratings N 100 250 500 1000 2500 5000 10000
(Lbs.) (22) (56) (112) (225) (562) (1124) (2248)
Size 01 01 01 01 01 01 02
Input Power
±12 to ±15 VDC @ 45 MA ±5%
Output Signal
5VDC output at rated load
Temperature Range
0-70 degrees C (32 -158 degree F)
Temperature drift
0.1 % of rating per degree C
Non-linearity and Repeatability
< 0.5%
Power Consumption
1 Watt
Cable
16 ft. provided with load cell
Maximum Load Ratings (See Figure 6)
Overload
120% of rated load
Compression Overload
150% of rated load
Horizontal Load
50% of rated load
Model Numbers/Part Numbers
FM01-100 6910-840-100 FM01-250 6910-840-102 FM01-500 6910-840-104 FM01-1000 6910-840-106 FM01-2500 6910-840-108 FM01-5000 6910-840-110 FM01-10K 6910-840-112
4
Model Size Load in N Amplifier built in
Alignment
Figure 1
The sensor has been factory calibrated:
0VDC (No load) 5VDC (Rated load)
Two potentiometers and LED’s are located near the “D” connector (See Figur cation. When used in the nominal range, both LED’s are “ON”. Although the load cell has been factory calibrated. The unit may be rescaled if necessary. It is recommended that a qualified technician do this procedure.
Attach a digital volt meter between the signal lead (yellow) and 0VDC (ground). With no load on the cell adjust the zero potentiometer for a 0VDC output. The zero setting LED should be “OFF”. Any voltage above 0VDC, the zero LED will turn “ON”.
Apply the mazimum load to the cell. Adjust the gain potentiometer for a 5VDC output reading. The gain LED should be “OFF” at a 5VDC output level. Remove the load and insure the gain LED is “ON”.
The zero and gain adjustments may need to be repeated a couple of times to insure proper set­ting.
e 1) for visual indi-
Wiring Hookup:
Red (+15V)
White (Ground)
Yellow (Signal)
BLUE (-15V)
+UCELL/SEN+
CELL1+/SENS IN
CELL1-
-UCELL/SENS Ground (OV) Shield +UCELL CELL2+
CELL2-
-UCELL SHIELD
FM Series Load Cell
MCS2000-CTLC
No Connection No Connection
No Connection No Connection
Add Jumper
Red (+15V)
White (Ground)
Yellow (Signal)
Blue (-15V)
+UCELL/SEN+
CELL1+/SENS IN
CELL1-
-UCELL/SENS Ground (OV) Shield +UCELL
CELL2+
CELL2-
-UCELL Ground (OV) Shield
Red (+15V)
White (Ground)
Yellow (Signal)
Blue (-15V)
N/C
N/C
FM Series Load Cell
FM Series Load Cell
MCS2000-CTLC
Magnetic Particle Brake
MCS2000-PSDRV
Power Supply
and Drive
MCS2000-
CTLC
FM Load
Cell
FM Load
Cell
The load cell requires a +15VDC and a -15VDC power supply. The 5V/15V switch inside the MCS2000-CTLC must set to +/-15VDC. Terminate all unused wires from cable.
Wiring example using One Load Cell with the MCS2000-CTLC contr
ol
Notes: It is recommended to use the load cell
in a compr
ession application. It must be fitted on a flat surface in order to avoid original sensitive plate stress. Do not load the sensor before mounting it with screws on the mounting surface.
System Example:
FM Load Cell with an Electric Brake
This is a typical load cell unwind application example. The electric brake varies the tension on the web depending on the feedback fr load cell. The load cell signal is amplified and interpreted in the controller (MCS2000-CTLC). The controller then puts out a corresponding 0-10 VDC signal to the power supply and drive (MCS2000-PSDRV). The PSDRV then amplifies and interprets the signal from the controller and puts out a corresponding 0-24 VDC signal to the brake to apply either more or less braking.
om the
Wiring example using 2 load cells with the MCS2000-CTLC control
Warner Electric • 800-825-9050 P-2012-1
Figure 2
Figure 3
Figure 3
Figure 4
5
Dimensions
G F
H
C
K
J
D
E
I
A B
M10 Screw 11 mm dia. (6)
L
Max. extension overload =
120% from nominal load
Max. horizontal load =
50% from nominal load
Max. compression overload =
150% from nominal load
Tension sensor
FM Series
Foot mounted load cells
(–) Denotes millimeters
Size Load Ratings A B C D E F G H I J K L
N (lbs.) 100 (22) 250 (56)
01 500 (112) 4.055 7.874 6.890 .512 4.016 .984 .984 3.150 2.047 .472 .236 .433
1000 (225) (103) (200) (175) (13) (102) (25) (25) (80) (52) (12) (6) (11) 2500 (562)
5000 (1124)
5.591 8.858 7.677 .669 5.00 .984 .984 3.937 2.165 .709 .236 .433
02 10000 (2248) (142) (225) (195) (17) (127) (25) (25) (100) (55) (18) (6) (11)
Figure 5
Figure 6
6
P-2012-2
819-0402
AC10 Measuring System
Warner Electric • 800-825-9050 P-2012-2
7
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.
8
System Overview
J3
J4
J6
J5
Warner Part# 80-165 Rev Serial#
Setup
Rapid
Exit
Setup
Enter
J7
J8
J9
J1
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.
Warner Electric • 800-825-9050 P-2012-2
9
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.
10
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.
Warner Electric • 800-825-9050 P-2012-2
11
Specifications
AC10 Tensioncells
Dimensions (I x w x h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.00" x 3.44" x 3.90"
Maximum Load Capacity (tension plus tar
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-10 to +10 VDC
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
e)
12
Pushbutton Key Functions
The six pushbutton keys on the PSAC10 board are used to enter and exit the Setup Mode and to make adjustments during the procedure. This section describes the various key functions and combi­nations that are used while setting up the system.
The UP arrow key is used to toggle between selections. It is also used to incremental-
RAPID
ly increase the output voltage each time the key is pressed. When the UP arrow and RAPID keys are pressed simultaneously, the voltage value will change continuously until the keys are released or the upper limit is reached. (See note below.)
ENTER
SETUP
EXIT
SETUP
RAPID
ENTERSETUP
RAPID
The DOWN arrow key is used to toggle between selections and to incrementally decrease the output voltage each time the key is pressed. When the DOWN arrow and RAPID keys are pressed simultaneously, the voltage value will change continuously until the keys are released or the lower limit is reached. (See note below.)
The ENTER key is used to make selections and store values before proceeding to the next Setup step.
Pressing and releasing these keys simultaneously accesses the Setup Mode. An aster­isk (*) will display next to the right tension value.
Press and release these keys simultaneously to start the Setup procedure when in the Setup Mode.
Press and release this key to exit the Setup Mode at any time. The system will return the settings entered during the last completed setup procedure.
Press and release these keys simultaneously to enter the settings for the Programmable Alarm Output.
SETUP
EXIT
Press and release these keys simultaneously to zero the system.
Note: During setup, the output voltage value will change approximately 5 millivolts each time the Up or Down arr
ow key is pressed and released. Pressing and releasing the RAPID key and the Up or Down arrow key simultaneously will change the value approximately 200 millivolts. Holding the Rapid key and an arrow key in, will continuously change the value until the keys are released.
Warner Electric • 800-825-9050 P-2012-2
13
Installation
T
E
B
TW
T
RF
L
O
Tensioncell Model Number Designation
AC10B 18 W1
Code
A B C
Max. Load
Capacity
(pounds)
60 170 500
Min. Tension
Load for Setup
(pounds)
4 10 30
Example: AC10B18W1 AC10 = Side Mount Tensioncell B = 170 pound capacity 18 = 1-1/8 inch shaft diameter W1 = AC10 with split brushing
Support Bushing (AC10 only)
W1 = Split bushing for clamping W2 = Solid bushing for expansion
08 1/2 09 9/16 10 5/8 11 11/16 12 3/4
13 13/16 14 7/8 15 15/16 16 1 17 1-1/16
18 1-1/8 19 1-3/16 20 1-1/4 21 1-5/16 22 1-3/8
23 1-7/16 24 1-1/2
Shaft Diameter
Pre-Installation Inspection
Before installing the AC10 system:
1. Insure all components are present. A typical system consists of two AC10 Tensioncells, one PSAC10 board, and two 30 foot lengths of cable for connecting the Tensioncells to the board. Refer to Model Number Designation (Chart 1) below to verify load capacity and shaft diameter.
2. Inspect all electrical and mechanical compo­nents for physical damage.
3. Promptly report any damage to the carrier and Warner Electric.
Mechanical Installation – Tensioncells
The maximum rated load capacity must be greater than or equal to (RF + TW) where W = Tare Weight. The Web Resultant Force (RF) and Tare Weight are always summed. Refer to the Model Number Designation (Chart 1) below to verify the shaft diameter, and that the maximum rated load capacity of each unit.
Warner Electric also recommends the Resultant Force (RF) be greater than 1/3 the maximum load capacity of the Tensioncells.
Warner Electric side mount AC10 Tensioncells are shipped in pairs designated W1 and W2. The W1 unit has a split stainless steel, self­aligning bushing for clamping the measuring roll. The bushing in the W2 unit is not split to allow for shaft expansion.
AC10 Tensioncells are available in three capaci­ty ranges. The rated load capacity should always be larger than the maximum calculated Tare Weight (W) plus the Resultant Force (RF).
To calculate the Resultant Force:
1. E = (180°-B/2) where B = Wrap Angle
2. RF = T x CosineE where T = Web Tension
14
Chart 1
Before installing the Tensioncells, refer to
T
E
B
TW
T
RF
L
O
5/8-11 UNC Mounting Bolt
Machine Frame
W1
Locating Tab
Centerline
Shaft Support Block & Screws
W2
machine drawings, or other documentation to determine the mounting angle. If the mounting angle is not specified, mount the Tensioncells so that the Tensioncell load line (OL) bisects the wrap angle and aligns with the Resultant Force (RF).
The Tensioncells are mounted to the machine frame with a 5/8-11 UNC bolt. The bolt is in line with the centerline of the shaft support bushing. This allows the T
ensioncells to be rotated around the centerline of the roll so that the Tensioncell load line (OX) aligns with the Resultant Force (RF).
To install the Tensioncells:
1. Drill a 5/8" diameter hole through each side
of the machine frame at the measuring roll location. The holes must be in line with each other and roll centerline to insure that the roll is level.
2. Fasten the Tensioncell to the machine frame
with the 5/8-11 UNC mounting bolt.
3. Rotate the Tensioncell to the proper mount-
ing angle and tighten the mounting bolt.
4. Drill a #6 (.204) hole concentric with the 1/4" hole in the locating tab.
5. Remove the Tensioncell to provide clearance to tap the hole for a 1/4-20 thread.
6. Repeat steps 2 through 5 for the Tensioncell for the other end of measuring roll shaft.
7. Loosen, but do not remove, the four screws in the bottom of the shaft support block enough to slide the Tensioncells on the roll shaft.
Note: The mounting angle must be the same for both T
ensioncells and the Load Plate for both units must face in the same direction.
8. Position the roll with the Tensioncells in the machine and fasten them to the machine frame with the mounting bolts. Tighten the bolts enough to allow the T
ensioncells to be
rotated to the desired mounting angle.
9. Rotate the Tensioncells to align the locating tab with the 1/4-20 threaded hole. Lock the Tensioncells in position against the machine frame using a 1/4-20 x 1/2 socket head cap screw.
10. Tighten the mounting bolt on each unit.
11. Align the measuring roll so that there is no mechanical binding or friction.
12. Tighten the four screws in the bottom of each shaft support block.
Note: The mechanical stops are factory set
ovide 1000% overload protection.
to pr
Warner Electric • 800-825-9050 P-2012-2
15
Electrical Installation
Oscillator
Demodulator
Shield to Pin H
Shield to Pin H
White to Pin G
Brown to Pin A
Pink to Pin E
Yellow to Pin C
Input
Output
P1
S1
S2
A
GH E C
A
H
G
C
D
E
FB
Sig Sig Exc Exc Gnd
Yellow Pink Brown White Shield
Yellow Pink Brown White Shield
Sig Sig Exc Exc Gnd
J2
J1
1
1
2
2
3
3
4
4
5
5
Electrical Connections
(Read the entire electrical installation proce­dure before proceeding.)
The PSAC10 Power Supply/Amplifier board should be secur
ely mounted in a cabinet or enclosure using the mounting holes and standoffs INPUT provided. Refer to the dimension drawing on Page 19 for mounting hole locations.
Two 30 foot cables are provided for connecting the AC10 Tensioncells with the PSAC10 board. A screw-on connector is provided at one end of each cable for connecting to the AC10 Tensioncells.
Note: If the board must be located more than 30 feet away fr
om the Tensioncells, the cable can be extended up to a total of 100 feet using Belden #8723 (or equivalent) in a grounded steel conduit.
Although either Tensioncell in the system can be designated as Tensioncell #1 or #2, the following electrical connections assume the AC10 Tensioncell marked W1 is Tensioncell #1 and the Tensioncell marked W2 is Tensioncell #2.
Notes:
1. The wire color connections listed for J1 and J2 will dif
fer if Belden #8723 (or equivalent) cable is required. lnsure the correct wiring connections are made with respect to the connection made with the Warner Electric supplied cable.
2. The Warner Electric supplied cable/connec­tor assembly is an eight conductor cable. However, only the yellow, pink, brown, and white and shield wires used.
J1 to W1 Tensioncell Terminal Connection with Warner Electric supplied cable
Terminal Label Description Wire Color
J1-1 Sig AC signal from LVDT Yellow J1-2 Sig
AC signal from LVDT Pink J1-3 Exc Excitation to LVDT Brown J1-4 Exc Excitation to LVDT White J1-5 Gnd Shield Shield
Note: Pins B, D & F are not used
Warner Electric Supplied Cable to Transducers
Tension signal from transducer 0-700mVAC, 5KHz
15 VAC, 5KHz excitation to the transducer
Tension signal from transducer 0-700mVAC, 5KHz
15 VAC, 5KHz excitation to the transducer
16
J2 to W2 Tensioncell Connection with Warner
Gnd L1 L2
J3
230V
1
2
3
X
X
2-Only
1-Only
Gnd
J5
Cell #2Cell #1
Total
1 2 3
2L1 1L1 2L2 1L2
J4
1 2 3 4
Electric supplied cable
Terminal Label Description Wire Color
J2-1
Sig AC signal from LVDT Yellow J2-2 Sig AC signal from LVDT Pink J2-3 Exc Excitation to LVDT Brown J2-4 Exc Excitation to LVDT White J2-5 Gnd Shield Shield
J3 Input Power (115/230 VAC, 1-PH, 50/60 Hz)
Terminal Label Description Wire Color
J3-1 Gnd Ground Green J3-2 L1 L1 (230V) or Hot (115V) Black J3-3 L2 L2 (230V) or Neutral (115V) White
Terminal Label Description
J4-1 2L1 (Switched) Line 1 J4-2 1L1 (Hot) Line 1 J4-3 2L2 (Switched) Line 2 J4-4 1L2 (Hot) Line 2
J5 Cell#1/Total/Cell#2 Switch Terminal (For Output #2 only)
Make sure voltage select switch is in proper position
Input Power single phase 115 or 230 VAC
The input voltage selector switch must corre­spond to the voltage of the input power source.
J4 AC Power Switch and/or Power Indicator Terminal
J4 provides the terminal connection for an exter­nal AC Power Switch and/or power indicator
. The indicator should not draw more than 40 milliamps of current. J4 may also be used to supply AC power to a digital voltmeter by connecting the meter between J4-2L1 and J4-2L2.
J5 provides the connections for an external three-position switch with two normally open contacts. When used in conjunction with a remote meter, the switch allows the user to monitor total tension or the tension applied to either Tensioncell. The meter should be connect­ed to Output #2 at J6, terminals Out2 and Gnd.
With the switch in the normally closed position, Output #2 will indicate the total tension. In the Cell#1 position, Output #2 switches to indicate the tension measured by the W1 Tensioncell. Changing to the Cell#2 position switches Output #2 to indicate the tension applied to the W2 Tensioncell.
Terminal Label Description
J5-1 2-Only (Switched) tension W1 J5-2 1-Only (Switched) tension W2 J5-3 Gnd Ground
Note: If an ON-OFF switch is not used, jumpers must be installed fr
om J4-2L1 to J4-1L1 and from J4-2L2 to J4-1L2 for proper operation.
Warner Electric • 800-825-9050 P-2012-2
17
J6 Analog Outputs Terminal
Out 2
Gnd
Out 1
Gnd
J6
Output #2 ( -10 to +10 VDC)
Common
Output #1 ( -10 to + VDC)
Common
1 2
3 4
Normally Closed
Common
Normally Open
J7
NC
COM
NO
1 2 3
Ground
Data Line -
Data Line +
J8
Gnd
Tx-
Tx+
1 2
3
The J6 terminal provides the connections for the two 10 volt DC outputs. Each output can provide up to 30 milliamp current.
During setup, each output is individually scaleable to meet the requirements needed to calibrate the indicator, drive, or control connect­ed to the board. The board circuitry is designed to allow a switch to be connected at Terminal J5. This switch allows the user to monitor the Output #2 signal with respect to total tension, or the ten­sion applied to either Tensioncell.
The contact may be wired to function in either the normally open or normally closed state.
Terminal Label Description
J7-1 NC Normally Closed Contact J7-2 J7-3 NO Normally Open Contact
COM Common
Terminal Label Description
J6-1 Out2 Scaleable -10 to +10 VDC Output J6-2 Gnd Common J6-3 Out1 Scaleable -10 to +10 VDC Output J64 Gnd Common
J7 Threshold Relay Terminal
J7 provides the connections for utilizing the AC10 Threshold Relay which is a form "C" dry relay contact, rated at 1 Amp. During setup, the threshold (percentage of total tension) is pro­grammed to operate when the total tension is either above or below the threshold value.
J8 RS232 Output Terminal
J8 provides the cable connections for interfac­ing the PSAC 10 board with a PC to monitor total tension and tension applied to each Tensioncell. Data is transferred in ASCII text for­mat.
Terminal Label Description
J8-1 Gnd Ground J8-2 Tx- Data Line + J8-3 Tx+ Data Line-
J9 (Spare)
Initial Electrical Checks
Before applying power:
Note: Make sure that the Input Power Selector Switch matches the available input voltage.
Switch 1 2 3 4 5 6 7 8 Position ON ON ON ON OFF ON ON ON
Apply power.
The red Run Mode LED in the lower right hand corner of the board should be flashing.
18
V
erify that the 8-position dip switch is set as follows:
AC10 Setup Procedure
Compression
Te nsion
Important: The input to any external device wired to J6-3 Out1 or J6-1 Out 2 must be 10 VDC or less.
4. Press ENTER when the desired mode is dis­played.
Steps 5 through 8 are performed with only the tar
e load applied on the Tensioncells.
The following procedure assumes a digital volt­meter will be used when measuring and setting the desired output voltages. If the outputs are connected to a digital or analog indicating device, which will be used during normal opera­tion, these devices may be used during the setup procedure.
Note: The voltage setting for Output #1 at 100% load must be mor
e positive than the voltage setting at 0% load. The same applies to the voltage settings for Output #2.
With power applied to the PSAC10 board, allow the system to "warmup" for 20 minutes or longer before proceeding with the setup proce­dure.
ess and release the SETUP and UP-
1. Pr ARROW keys simultaneously. An asterisk (*) will display next to the right tension value.
Note: To exit the SETUP mode at anytime dur­ing the following pr
ocedure, press and release the EXIT key. The system will return to the set­tings entered during the last completed setup.
5. Apply Load 0%
Insure that the Tensioncells are properly installed and the material is r
emoved from
the measuring roll.
6. Press ENTER.
0% 0% *0%
2. Press and release SETUP & ENTER simulta­neously to start the SETUP pr
ocedure.
Note: The Run Mode LED should stop flashing.
Compression Mode
3. Select either the COMPRESSION MODE or
TENSION MODE using the UP or DOWN arrow key to toggle between the two choices.
Select the COMPRESSION MODE if the
a.
direction of the tension force is toward the base block.
b. Select TENSION MODE the direction on
the tension force is away from the base block.
Warner Electric • 800-825-9050 P-2012-2
19
7. Adjust Out 1 0%
Out 2
Gnd
Out 1
Gnd
J6
Output #2 ( -10 to +10 VDC)
Common
Output #1 ( -10 to + VDC)
Common
1 2
3 4
Scale
W eb Path
Roll
Rope
W eb Path
Roll
Rope
W eights for Max. Tension
a. Connect a digital voltmeter between J6-3
Out 1 and J6-4 Gnd. Press the UP or DOWN arrow key (and
b.
RAPID key if necessary) until the desired no load output voltage is attained.
c. Press ENTER.
Note: All rolls used in the pull test should be free running rolls.
c. With one end of the rope secured, hang a
weight equal to the full load tension. (50% if selected)
A crane scale may be used to apply the
equired load.
r
d. Press ENTER.
10. Adjust Out 1 100% a. Connect a digital voltmeter between J6-3
Out 1 and J6-4 Gnd.
8. Adjust Out 2 0% a. Connect a digital voltmeter between J6-1
Out 2 and J6-2 Gnd. Press the UP or DOWN arrow key (and
b.
RAPID key if necessary) until the desired no load output voltage is attained.
c. Press ENTER.
Note: Steps 9 through 12 can be performed with 50% or 100% load applied when setting Output #1 and Output #2 voltage. Refer to the table at the right for minimum r
esultant
load required for setup before proceeding.
9. Apply Load 100% a. Press the UP or DOWN arrow key to tog-
gle between 50% or 100%. When desir percentage is displayed.
ed
b. Pr
ess the UP or DOWN arrow key (and RAPID key if necessary) until the desired full load output voltage is attained.
c. Press ENTER.
b. Thread a non-stretchable rope over the
20
The illustrations at the right show two pull test methods. These tests are used to apply a load representative of the web tension. The load should be equal to the percentage of the full load selected (50% or 100%).
center of the tension measuring roll simu­lating the web path.
Model Max Load Min. Tension
Capacity Load for Setup
(Pounds) (Pounds) ACIDA 60 4 ACIDB 170 10 ACIDC 500 30
Table 2
11. Adjust Out 2 100%
5. Press ENTER to select the desired mode.
a. Connect a digital voltmeter between J6-1
Out 2 and J6-2 Gnd. Press the UP or DOWN arrow key (and
b.
RAPID key if necessary) until the desired output voltage is attained.
c. Press ENTER.
12. Setup Complete a. Press ENTER.
Programmable Threshold Relay
The Threshold Relay can be programmed to Close on Higher (if the total tension goes above) or Close on Lower (if the total tension goes below) a preset programmable threshold between 0% and 102% of the total tension. The dry relay contact is rated at 1 amp @ 24VDC, 250mA @ 220 VAC, or 500 mA @ 120 VAC.
Note: The threshold may be set while the web machinery is in operation. Although the LCD will not be showing the tension, Output #1, Output #2, and the serial output will still be r
esponding to tension changes.
If the threshold value or mode is reset with the equipment operating, the new value will take
fect immediately.
ef
Reset Tare to Zero
The tare value may be zeroed to compensate for any offsets accumulated during normal oper­ation. Press the SETUP and EXIT keys simulta­neously to reset the tare to zero.
Note: Resetting tare to zero must be done with no tension load applied.
A lamp may be connected between J7-3 NO (or J7-1 NC) and J7-3 COM during setup, start up, and/or normal operation to verify the relay is operating properly.
To set the threshold value:
1. Press the SETUP & RAPID keys simultane-
ously. The display will show a message indi­cating the current value of the threshold. The Run Mode LED will continue to flash.
Threshold 000%
2. Press the UP or DOWN arr
ow key until the
desired threshold value is displayed.
3. Press ENTER to select the value.
4. Press the UP or DOWN arrow key to toggle
between the CLOSE ON LOWER or CLOSE ON HIGHER prompt.
Close on Lower
Warner Electric • 800-825-9050 P-2012-2
21
Troubleshooting
Test Points TP5, TP6, TP7, TP8, TP9
Enter
J7
J8
J9
LCD Brightness Adjustment
+5VDC
-5VDC
-5VDC
+5VDC
GND
Test Points TP2, TP3, TP4
When properly installed in accordance with the design specification and procedures outlined in this manual, the AC10 Tension Measuring System should require little or no regular main­tenance or service. Certain conditions, however, can impair the accuracy, reliability, and perform­ance of the system. The following are some conditions to consider which may effect the mechanical and/or electrical components of the system.
1. Have the system operating parameters changed?
a. Has the web tension changed? b. Does the tension plus tare load exceed
the maximum rated load capacity of the unit?
9. Verify the following voltages. TP3 to TP7 +10 volts DC TP4 to TP7 +2.5 volts DC TP5 to TP7 +15 volts DC TP6 to TP7 +5volts DC TP8 to TP7 -5 volts DC TP9 to TP7 -15 volts DC
10. Are outputs responding to tension changes? Check connections and voltages at J1, J2, and J6.
11. Does the output signal(s) from the board meet the voltage requirements for the device(s) connected to it?
12. Is the Excitation Voltage to the LVDTs cor­rect?
c. Has the Wrap Angle changed?
2. Are the Tensioncells mounted correctly and securely?
3. Is the tension measuring roll properly aligned and does it turn freely?
4. Is the line voltage present and the on-board Input Power Selector Switch in the correct position?
5. Is an external power switch connected and operating correctly? If an external switch is not used, are the jumpers properly installed at J4? See page 11.
6. Are all fuses and/or circuit breakers installed and functional? There are two 250V, 500mA fuses on the board.
7. Is the Run Mode Indicator LED flashing? If not, check if the system is in Setup mode.
8. Is the on-board display lit? Check LCD Brightness Adjustment.
22
a. Using an AC volt meter with at least
5Khz band width, measure the voltage between J1-3 Exc and J1-4 Exc. The meter should read 15Vrms ~ 5Khz ± 5%. If excitation voltage is low, turn off power to the board and remove the J1 connector. Turn power back on and recheck. If voltage is correct, check for a short in Tensioncell cable assembly. Repeat test for Cell #2 at J2.
b. With board power off, remove the J1
connector and measure the resistance between the Yellow (J1-1 Sig) and Pink (J1-2 Sig) wire terminals. The resistance reading should be 335 ohms ± 5%. The resistance between White (J1-3 Exc) and Brown (J1-4 Exc) wire terminals should be 100 ohms ± 5%. If readings are incor­rect, disconnect cable at the Tensioncell designated as Cell #1, and check resist­ance between pins C and E, and A and G. Repeat test for Cell #2 at J2.
13. Does the system zero? Press the SETUP and EXIT keys simultaneously.
14. Does repeating Setup procedure help?
15. If problem(s) persists, contact your local Warner Electric Representative or the factory.
Warner Electric • 800-825-9050 P-2012-2
23
See Note
3.13
2.13
3.44
1.13
5/8-11 UNC .93 Full Th’d for Mounting Bolt
Electrical Connector
2.50
.25 Dia. Hole For Locking Screw
3.90
1.13
2.00
.75
3.00
Note:Stainless steel self-aligning bushing provided
for 1/2” to 1-1/2” diameter shafts in 1/16” increments.
+
.50
2.00
.25
1.31
1.44
W2 unit shown here. W1 unit is available.
AC10 Tensioncell Dimensional Drawings
(Specifications and dimensions subject to change without notice.)
Tensioncell Model Number Designation
A C 1 0 B 1 6 W 1
Max.Load Min.Tension
Code Capacity Load for Setup Support Bushing (AC10 only)
(pounds) (pounds) W1 = Split bushing for clamping
A 60 4 W2 = Solid bushing for expansion B 170 10 S = System, which includes one “W1” cell, C 500 30 one “W2” cell, two 30 ft cables and a
Examine: AC10B16W1 Shaft Diameter AC10 = Side Mount Tensioncell B = 170 pound capacity 16 1 16 = 1 inch shaft diameter 20 1-1/4 W1 = AC10 with split bushing 23 1-7/16
12 3/4
PSAC10 board.
24
Note: Other shaft diameters are available.
PSAC10 Board Dimensions
1.31
.31
.25
5.75
3.13
J3
J4
6.88
6.25
3.13
Mounting Holes .250 Dia. (7) Places
J6
J5
8.25
Warner Part# PSAC10 Serial#
Setup
Rapid
Exit
Setup
Enter
J7
8.75
J8
J9
J1
J2
Specifications and dimensions subject to change without notice.
Warner Electric • 800-825-9050 P-2012-2
25
26
P-2012-3 819-0403
A30 Single Range Tensioncells
Warner Electric • 800-825-9050 P-2012-3
27
Description
Damper
C-Flexure
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
28
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
When Supplied
with Cable
(1) Red + DC (2) Black – DC
(3) Green – Signal (4) White + Signal
C D
BAC
D
.030
ion
Output vs 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 out­put 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
Figure 3
LVDT Output vs. Deflection Chart
Figure 4
29
E. Description of Operation
E
D
H
E
RF
N
TW
T
T
The 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.
The resultant tare is minimized by mounting the Tensioncell so that (N) is 31°. (See Figure 6)
Figure 5
30
Figure 6
Installation and Operation 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 con­tainer 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 rotating 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 r assembly with Tensioncells to be lifted out of the machine.
oll
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 mirr
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 rotated around the centers of the measuring roll and mounting bolt to achieve the proper mounting angle. (Description of Operation on Page 5)
or image of the other. (See Figure 7)
Figure 7
Warner Electric • 800-825-9050 P-2012-3
31
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 mount­ing 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 mount­ing 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
32
Set up and Adjustments Specifications
Roll
Rope
Web Path
Weights for
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
ovide a 0.5 to 6.5 volts DC output signal.
pr
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.)
With one end of the rope secured, hang a
2. 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)
Apply 24 volt DC electrical power to the
3. 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 befor insure accurate readings.
e taking first readings to
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. Measur
e 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 volt­age.
Warner Electric • 800-825-9050 P-2012-3
(Figure 9)
33
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, turn 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?
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
Electrical
1. Are LVDTs receiving correct input voltage? Check line voltage, fuses or circuit breakers,
and power switches. Check power supply
If LVDT circuits are open or shorted, replace LVDT. Contact Warner Electric with tensioncell model number and serial number.
excess of 5 megohms.
output and voltage to LVDTs.
2. Are all connections secure? Check for continuity. Retighten all connec-
tions. Recheck operation.
34
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 required.
Series Number (2 Digits)
30 Wall Mount
B A 3 0 T 1 6 K W1
Capacity Range
See Table 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
35
3.75
for Locking
** 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 3/4 1.0
1-1/4
Inches 12 16 20
Table I-B
Note: Other shaft diameters are available as special
. Contact Warner Electric for other shaft
order diameter availiblilty.
36
P-2012-4 819-0404
B30 Single Range Tensioncells
Warner Electric • 800-825-9050 P-2012-4
37
Description
W1
W2
Machine Frame
B30 Series Tonsioncell Single Bolt Mounting
Internal Bearing
Damper
C-Flexure Far Side
Mechanical Stop
Load Plate
LVDT LVDT
Core
General Information
Warner Electric Series 30 Type B Tensioncells are force transducers especially designed to measure and control web tension on continuous strip processing lines. They are normally installed in matched pairs at each end of a measuring roll. (See Figure 1)
A Tensioncell consists of a unique combination of two integral systems (one mechanical, the other electrical) for converting the mechanical force of strip tension into an electrical signal which is directly proportional to the strip ten­sion.
Type "B" Tensioncells are intended for NON­ROTATING shaft installations. A self-aligning shaft clamp assures proper alignment of the measureing roll when the tension cells are bolt­ed to the machine frame. Type "B" Tensioncells are supplied in matched pairs, one to be mount­ed at each end of the tension measuring roll. Note that the cell marked "W2" is a mirror image of "W1". The 'W2" cell allows for thermal expan­sion of the shaft. (See Figure 1)
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.
Figure 2
38
Type B - Bearings in Roll - Non-Rotating Shaft
Figure 1
For our discussion here, deflection of the Load
DC
Signal
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 Page 3, Figure 2)
Type "K" DC LVDT
As illustrated in Figure 3, a DC LVDT consists of the following components:
• An oscillator, 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)
The Electrical System
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 movable core of the LVDT is mechanically coupled to the Load Plate by means of the Core Adjust Assembly. (See Figure
3) This adjustment is factory set and is not accessible.
• A demodulator and summing network to rectify and integrate the currents from the Secondary Coils
Figure 3
Warner Electric • 800-825-9050 P-2012-4
39
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
With Warner Electric LVDTs, the input and out­put 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)
LVDT Output vs. Deflection Chart
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.
In standard applications, where two Tensioncells are used, the inputs may be connected in paral­lel allowing the Tensioncells to be excited from the same power supply. The LVDT outputs are then summed to obtain a signal representing the strip tension and tare loads distributed across the roll.
40
Description of Operation
The 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)
(Figure 5)
TT
N
TW
D
T
T
H
J
E
E
Figure 6A
Figure 6B
T
T
TW
J
N
D
H
E
E
N
T
T
E
E
H
J
D
TW
Figure 7B
N
TW
E
E
H
T
J
T
D
Figure 7A
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 change in 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.
The resultant tare is minimized by mounting the Tensioncell so that (N) is 149° (See Figures 6A and 6B) or so that (N) is 329° (See Figures 7A and 7B).
Warner Electric • 800-825-9050 P-2012-4
41
Installation and Operation 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 container 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.
Handling
Tensioncells can be handled manually.
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 rotated around the centers of the measur­ing roll and mounting bolt to achieve the proper mounting angle (Description of Operation on Page 5).
The locating tab prevents the Tensioncell from rotating 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 r assembly with Tensioncells to be lifted out of the machine.
oll
Long Term Storage
While Warner Electric loadcells are plated, exposure to weather, dirt, or moisture should be avoided when they are stored.
Mechanical Installation
Note: Refer to the Dimension Drawing
Pages 11 and 12 of this manual for detailed identification of all parts.
Tensioncells are designated as W1 and W2, one being the mirror image of the other to pr for mounting between two fixed walls. (See Figure 8)
ovide
To install Tensioncells:
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.
2. Fasten the Tensioncell to the machine frame with the mounting bolt.
3. Rotate the Tensioncell to the proper mount­ing angle and tighten the mounting bolt. (Refer to N 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. Repeat steps 1 through 5 for the Tensioncell to be mounted at the other end of the meas­uring roll.
42
7. Assemble the tensioncells onto the ends of the measuring roll shaft.
Figure 8
Warner Electric • 800-825-9050 P-2012-4
8. Position the roll with the Tensioncells on the
X
DC
Signal
machine and fasten with the mounting bolts.
9. Rotate the Tensioncells to the proper mount­ing angle and tighten the mounting bolts.
10. Lock the locating pad for each Tensioncell against the machine frame using the 1/4-20 x 1/2 socket head capscrew.
11. Tighten the shaft in the mounting block on the W1 unit. (The shaft end at W2 is left free to allow it to move as the shaft expands with temperature changes).
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.
Specifications
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
ovide a 0.5 to 6.5 volts DC output signal.
pr
The Mechanical Stops are fixed for the required travel of the Load Table.
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 9)
4. Connect the positive (+) output lead to Pin D and the negative (-) output lead to Pin C. (See Figure 9)
5. Repeat Steps 1 through 4 of the electrical wiring procedure for the Tensioncells mount­ed on the other end of the measuring roll.
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 9)
Warner Electric • 800-825-9050 P-2012-4
43
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 befor
e taking first readings to
insure accurate readings.
4. Measure the output voltage of the LVDT between the Gr
een and White 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 volt­age.
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. (See calibration sheet for voltage output.)
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.)
3. With a voltmeter connected to Pins C and D of the connector, an output voltage will be observed.
4. Repeat Step 3 for the Tensioncell mounted on the opposite end of the measuring roll.
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.
Trouble Shooting
When properly installed in accordance with the original design specifications Warner Electric tensioncells should require little or no regular maintenance or service.
2. With one end of the r
ope 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 10)
44
Figure 10
Certain conditions, however, can impair their inherently accurate and reliable performance. Therefore, if trouble should arise, the following conditions should be checked. (Continued on next page)
Mechanical
X
DC
Signal
1. Has the tension measuring system been changed?
a. An increase or decrease in strip tension
(Refer to A on the calibration sheet for specified strip tension.)
b. An increase or decrease in the wrap
angle. (Refer to B on the calibration sheet for the specified wrap angle.)
If the above parameters have been changed enough to prevent the unit from operating within the limits of the fixed. Mechanical Stops, replace­ment of the tensioncells required. For this modifi­cation, the Tensioncell should be returned to the factory with complete specifications.
2. Are the loadcells mounted securely?
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 the Tensioncell LVDT. Contact Warner Electric with Tensioncell model number and serial number.
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 a different Tensioncell.
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.
3. Are LVDTs open or shorted?
To check, turn off power and disconnect the input and output leads. Check coil continuity and resistance. (Refer to Figure 11)
a. Pin A to Pin B (Primary Coil) should be in
excess of 2 megohms.
Figure 11
b. Pin A or Pin B to LVDT shell should be in
excess of 5 megohms.
Warner Electric • 800-825-9050 P-2012-4
45
Model Number Nomenclature Example
Electrical
Connection B - MS Connector
Type
B - Non-Rotating Shaft
Series 30, Type B Specifications – Non-Rotating Shaft Mounting
Series Number (2 Digits)
30 Wall Mount
B B 3 0 P 1 6 K W1
Capacity Range
See Table II-A
K - DC LVDT with
Maximum 3 VDC Output Change Including Tare Displacement
Shaft Diameter
Shaft Mounting Configuration
W1-Split bushing W2-Solid bushing
Example Shown:
BC30P16KW1
N = MS Connector C = Rotating Shaft 30 = Series 30, Wall Mount P = 0-20 lbs. Capacity 16 = 1” Diameter Shaft K = K Type DC LVDT W1 = Split Bushing
See Table ll-B
Series 30, Type B – Nominal Capacity Ranges
Code P T U X Z Pounds 0-20 0-50 0-90 0-200 0-500
Table II-A
Note: Other Load ranges are available on special order. Contact Warner Electric for ratings & abalability.
46
3.75
2.88
3.63
2.31
RH
2.44
1.56
1.63
1.06
1.82
3.13
.94
**Warner Electric wall mounted tensioncells are located by a 5/8-11 bolt at the roll centerline and locating tab which
maintains rotational position of the tensioncell. (See Page 6.)
Notes:
W1 unit shown here. W2 unit is applied at the opposite end of the r
oll.
W1 unit clamps the shaft while W2 allows for
temperature expansion of the roll.
Both units have self-aligning feature.
Series 30, Type B Shaft Diameter Code
Code 12 16 20 23 Inches 3/4 1.0 1-1/4 1-7/16 RH 1.00 1.13
Table II-B
Note: Other shaft diameters are availible in special order.
Contact Warner Electric for other shaft diameter avalibility.
Warner Electric • 800-825-9050 P-2012-4
47
48
P-2012-5 819-0405
C30 Single Range Tensioncells
Warner Electric • 800-825-9050 P-2012-5
49
Description
W1 W2
Machine Frame
C30 Series Tensioncell Single Bolt Mounting
General Information
Warner Electric Series 30 Type C Tensioncells are force transducers especially designed to measure and control web tension on continuous strip processing lines. They are normally installed in matched pairs at each end of a measuring roll. (See Figure 1)
A Tensioncell consists of a unique combination of two integral systems (one mechanical, the other electrical) for converting the mechanical force of strip tension into an electrical signal which is directly proportional to the strip ten­sion.
Type "C" Tensioncells are intended for ROTAT­ING shaft installations. They are supplied with self-aligning ball bearings to assure positive alignment of the measuring roll. Type "C" Tensioncells are supplied in matched pairs, one to be mounted at each end of the tension meas­uring roll. Note that the cell marked "W2" is a mirror image of "W1". The 'W2" cell allows for thermal expansion of the rotating shaft. (See Figure 1)
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.
Figure 2
Self-Aligning Bearings in Tensioncell - Rotating Shaft
Figure 1
50
For our discussion here, deflection of the Load
X
DC
Signal
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 Page 3, Figure 2)
The Electrical System
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 2) The movable core of the LVDT is mechanically coupled to the Load Plate by means of the Core Adjust Assembly. (See Figure
3) This adjustment is factory set and is not
accessible.
Type "K" DC LVDT
As illustrated in Figure 4, 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
Figure 3
Warner Electric • 800-825-9050 P-2012-5
51
.030
io
Output vs Deflection
With Warner Electric LVDTs, the input and out­put 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)
LVDT Output vs. Deflection Chart
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.
In standard applications, where two Tensioncells are used, the inputs may be connected in paral­lel allowing the Tensioncells to be excited from the same power supply. The LVDT outputs are then summed to obtain a signal representing the strip tension and tare loads distributed across the roll.
Description of Operation
The 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)
52
(Figure 5)
TT
N
TW
D
T
T
H
J
E
E
Figure 6A
Figure 6B
T
T
TW
J
N
D
H
E
E
N
T
T
E
E
H
J
D
TW
Figure 7B
N
TW
E
E
H
T
J
T
D
Figure 7A
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 change in 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.
The resultant tare is minimized by mounting the Tensioncell so that (N) is 149° (See Figures 6A and 6B) or so that (N) is 329° (See Figures 7A and 7B).
Warner Electric • 800-825-9050 P-2012-5
53
Installation and Operation 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 container 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.
Handling
Tensioncells can be handled manually.
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 rotated around the centers of the measur­ing roll and mounting bolt to achieve the proper mounting angle (Description of Operation on Page 6).
The locating tab prevents the Tensioncell from rotating 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 r assembly with Tensioncells to be lifted out of the machine.
oll
Long Term Storage
While Warner Electric loadcells are plated, exposure to weather, dirt, or moisture should be avoided when they are stored.
Mechanical Installation
Note: Refer to the Dimension Drawing
Pages 11 and 12 of this manual for detailed identification of all parts.
Tensioncells are designated as W1 and W2, one being the mirror image of the other to pr for mounting between two fixed walls. (See Figure 8)
ovide
To install Tensioncells:
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.
2. Fasten the Tensioncell to the machine frame with the mounting bolt.
3. Rotate the Tensioncell to the proper mounting angle and tighten the mounting bolt. (Refer to N 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. Repeat steps 1 through 5 for the Tensioncell to be mounted at the other end of the measuring roll.
54
7. Assemble the tensioncells onto the ends of the measuring roll shaft.
Figure 8
Warner Electric • 800-825-9050 P-2012-5
8. Position the roll with the Tensioncells on the
X
DC
Signal
machine and fasten with the mounting bolts.
9. Rotate the Tensioncells to the proper mount­ing angle and tighten the mounting bolts.
10. Lock the locating pad for each Tensioncell against the machine frame using the 1/4-20 x 1/2 socket head capscrew.
11. Tighten the shaft in the mounting block on the W1 unit. (The shaft end at W2 is left free to allow it to move as the shaft expands with temperature changes).
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.
Specifications
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
ovide a 0.5 to 6.5 volts DC output signal.
pr
The Mechanical Stops are fixed for the required travel of the Load Table.
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 posi-
tive (+) input lead to Pin A and the negative (-) input lead to Pin B. (See Figure 9)
4. Connect the positive (+) output lead to Pin D
and the negative (-) output lead to Pin C. (See Figure 9)
5. Repeat Steps 1 through 4 of the electrical
wiring procedure for the Tensioncells mount­ed on the other end of the measuring roll.
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 9)
Warner Electric • 800-825-9050 P-2012-5
55
3. Apply 24 volt DC electrical power to the
T
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 befor
e taking first readings to
insure accurate readings.
4. Measure the output voltage of the LVDT between the Gr
een 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 volt­age.
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. (See calibration sheet for voltage output.)
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.)
3. With a voltmeter connected to Pins C and D of the connector, an output voltage will be observed.
4. Repeat Step 3 for the Tensioncell mounted on the opposite end of the measuring roll.
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.
Trouble Shooting
When properly installed in accordance with the original design specifications Warner Electric tensioncells should require little or no regular maintenance or service.
2. With one end of the r
ope 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 10)
56
Figure 10
Certain conditions, however, can impair their inherently accurate and reliable performance. Therefore, if trouble should arise, the following conditions should be checked. (Continued on next page)
Mechanical
X
DC
Signal
1. Has the tension measuring system been changed?
a. An increase or decrease in strip tension
(Refer to A on the calibration sheet for specified strip tension.)
b. An increase or decrease in the wrap
angle. (Refer to B on the calibration sheet for the specified wrap angle.)
If the above parameters have been changed enough to prevent the unit from operating within the limits of the fixed. Mechanical Stops, replace­ment of the tensioncells required. For this modifi­cation, the Tensioncell should be returned to the factory with complete specifications.
2. Are the loadcells mounted securely?
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 the Tensioncell LVDT. Contact Warner Electric with Tensioncell model number and serial number.
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 a different Tensioncell.
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.
3. Are LVDTs open or shorted?
To check, turn off power and disconnect the input and output leads. Check coil continuity and resistance. (Refer to Figure 11)
a. Pin A to Pin B (Primary Coil) should be in
excess of 2 megohms.
Figure 11
b. Pin A or Pin B to LVDT shell should be in
excess of 5 megohms.
Warner Electric • 800-825-9050 P-2012-5
57
Model Number Nomenclature Example
Electrical
Series Number (2 Digits)
Connection B - MS Connector
30 Wall Mount
B C 3 0 P 1 6 K W1
Type
C - Rotating Shaft
Capacity Range
See Table II-A
Series 30, Type C Specifications – Rotating Shaft Mounting
K - DC LVDT with
Maximum 3 VDC Output Change Including Tare Displacement
Shaft Diameter
See Table ll-B
Shaft Mounting Configuration
W1-Split bushing W2-Solid bushing
Example Shown:
BC30P16KW1
N = MS Connector C = Rotating Shaft 30 = Series 30, Wall Mount P = 0-20 lbs. Capacity 16 = 1” Diameter Shaft K = K Type DC LVDT W1 = Split Bushing
Series 30, Type C – Nominal Capacity Ranges
Code P T U X Z Pounds 0-20 0-50 0-90 0-200 0-500
Table II-A
Note: Other load ratings are available as special order.
Contact Warner Electric for ratings and availability.
58
for Locking
**Warner wall mounted tensioncells are located by a 5/8-11 bolt at the roll centerline and locating tab which maintains rotational position of the tensioncell. (See Page 6.)
Notes:
W1 unit shown here. W2 unit is applied at the opposite end of the roll. W1 unit clamps the shaft while W2 allows for
temperature expansion of the roll.
Both units have self-aligning feature.
Series 30, Type C Shaft Diameter Code
Code 12 16 20 23 Inches 3/4 1.0 1-1/4 1-7/16 RH 1.31 1.38 1.69 RT 3.81 4.131.00 | 1.13
Table II-B
Note: Other shaft diamters are available as special order. Contact Warner
Electric for ratings and availability.
Warner Electric • 800-825-9050 P-2012-5
59
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 7/05 Printed in USA
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