How it Works
Warner Electric
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FM Series
User Manual
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User Manual
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Warner Electric FM Series User Manual

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:
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