WEB CONTROL PRODUCTS
Contents
1. WEB CONTROL PRODUCTS User Manual gt gt gt x MB Tension Sensor accordance with Nexen s established policy of constant product improvement the specifications contained in this manual are subject to change without notice Technical data listed in this manual are based on the latest information available at the time of printing and are also subject to change without notice Technical Support 800 843 7445 651 484 5900 www nexengroup com DANGER Read this manual carefully before installation and operation Follow Nexen s instructions and integrate this unit into your system with care This unit should be installed operated and maintained by qualified personnel ONLY Improper installation can damage your system or cause injury or death Comply with all applicable codes Nexen Group Inc 560 Oak Grove Parkway Vadnais Heights Minnesota 55127 ISO 9001 Certified Copyright 2009 Nexen Group Inc FORM NO L 20127 H 0109 ii Table of Contents Theory of Operation a UUJJJJJTJUJJJJJ JJ 1 Installation T JJJ JJ JJ JJ J 2 Electrical Connections J JJ J JJ JJ JJF JJJJJJJ1 3 Sensor Roll JJ JJ J JJJJJJJ JJ JCJ 4 Sizing Sensors JT TJJJJJJsJJJJJJJJJJJJJJJJFJJ JJJJJ JJJJ 4 Tare Forces JJ JJJJJ J JcJJJJJJ 4 Web Forces J J TsJJJJJCJJJ JrT JJJJ JJJ J2. NOTE When using 5 MB11 or MB25 reverse wrap switch yellow or white and green wires at the Tension Controller or Tension Meter See appropriate instruction Manual FORM NO L 20127 H 0109 Set Screw Pillow Block Bearing Sensor Roll Span MBTension Sensor Sensor Span FIGURE 7 MBTEnsion Sensor Inclination of Detector Mounting Surface FIGURE 8 Yellow or White Signal Common Red 6VDC Excitation Black Excitation Common Green Signal 400mV FIGURE 9 FRONT VIEW OF CONNECTOR SENSOR ROLL The Sensor Roll which transfers the force generated by web tension to the MB Tension Sensors may be made of any material compatible with the materials being handled and the system requirements Dimensional considerations for designing the Sensor Roll are length and diameter The length of the roll should be short enough to allow for some lateral adjustment when installing the roll between the bearings The diameter must be designed to accommodate web speed and bearing life Weight may also be a design factor particularly when dealing with very low web tensions In low tension systems a heavy roll may cause false tension readings Bearings selected for low tension systems should have low frictional resistance for the same reason Unbalance in the Sensor Roll is picked up by the MB Tension Sensors causing false readings Dynamically balance the Sensor Roll to tolerance as shown See Figu
3. e Mounting surfaces must be parallel to one another Self centering Pillow Block Bearings are required to take up any variations in parallelism See Figure 8 WARNING Non compliance with the above conditions will induce heavy side loads within the MB Tension Sensor This will cause hysteresis and the MB Tension Sensor will measure mechanical resistance rather than tension load In extreme cases it will mechanically damage the MB Sensors MBOS is normally mounted using the sidewall mounting plate and cap screws provided Aside wall mounting bracket for the MB1 1 is available from Nexen The part number is 31084 NOTE Due to the high forces generated a side wall mounting bracket is not recommended for MB Tension Sensors MB33 and MB41 Mount these MB Tension Sensors to a rigid horizontal or near horizontal surface ELECTRICAL CONNECTIONS Use 16 Ft 5 m cables provided with MB Tension Sensors to make connections with Tension Controller Tension Amplifier or Tension Meter NOTE If you are using a Nexen controller refer to the appropriate instruction manual For all other controllers see Figure 9 Cables may be extended up to 500 156 with customer supplied four conductor 18 AWG shielded cable Be certain to maintain continuity of shield when splicing cable Longer cables 30 50 75 and 100 Ft are available from Nexen if an unspliced cable is required Gee REPLACEMENT CABLE ASSEMBLIES Page 9
4. D is gt 25 consult factory If D is lt 25 proceed with force calculation For Normal Wrap Where Resultant Force T Web Tension F T cos T cos B For Reverse Wrap Where F Resultant Force T Web Tension F cos cos FORM NO L 20127 H 0109 FIGURE 11 Reverse Wrap Pivot Point FIGURE 12 NOTE When installing MB Tension Sensors with asymmetrical wrap angle A must be on the same side as the Pivot Point or angle A must be on the side away from the Pivot Point MOUNTING DIMENSIONS os 16 4 5M From Bottom Cable 16 08 2 09 53 75 4 Drill 4 5 19 Spot Facing 9 Dia X 5 5 69 17 5 i Roll Center 175 4 7 Dia Mounting Position Holes Wall Mounting Bracket FIGURE 13 MBO5 continued 6 FORM NO L 20127 H 0109 MOUNTING DIMENSIONS continued 2 09 53 FIGURE 14 MB11 FIGURE 15 MB25 FORM NO L 20127 H 0109 Pivot Point 16 4 5M Cable Pivot Point 11 2 8 62 16 continued 7 MOUNTING DIMENSIONS c continued HRE Cable Pivot Point FIGURE 16 MB33 5 472 V 590 139 4 527 15 115 16 4 5 M 12 992 1 330 4 Mtg Holes 13 937 551 14 Dia 354 FIGURE 17 MB41 8 FORM NO L 20127 H 0109 SPECIFICATIONS Load range per sensor bo 22 44 22 44 110 2 1100 2200
5. 5 e MR RM NE RENE E M z 5 aso 220 770 15154 6 VDC Excitation 0 400 mV return 14 to 140 10 to 60 C REPLACEMENT CABLE ASSEMBLIES amp CONNECTORS NOTE All MB Tension Sensors are shipped with 16 ft 5 m cables standard Various cable sizes and replacement cable ends are available See Chart Below The MB Tension Sensors have No Field Serviceable parts If service is required contact your local Nexen Web handling distributor Description 18 in 457 mm Extension Cable 48 in 1 2 m Extension Cable 16 ft 5m Load Cell Cable Load Cell Cable 50 ft 15m Load Cell Cable 75 ft 23m Load Cell Cable 100 ft 30m Load Cell Cable Load Cell Pig Tale Cable Male Connector End Load Cell Cable Female Connector End Female End Part 2661 16 5m long cable provided with the sensor Male End Part 2660 FIGURE 18 FORM NO L 20127 H 0109 9 WARRANTY Warranties Nexen warrants that the Products will be free from any defects in material or workmanship for a period of 12 months from the date of shipment NEXEN MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED AND ALL IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED This warranty applies only if a the Product has been installed used and maintained in accordance with any applicable Nexen installation or maintenance manual for the Pr
6. JJ J 4 Mounting Dimensions JJ JJJJ JJ a 6 Specifications JJ JJJJJJJJJJJJJJJJJJJJJJJJTJJJJJJ JJJJJ 9 Replacement Cable Assemblies and Connectors TJ JJJJ U 9 s sses ssssssssssssssssstasssssssssssssssssssussssssspusssssssssssssss sasssscasssssssssss s assasssssssssssssssss 10 ili FORM NO L 20127 H 0109 THEORY OF OPERATION MB Tension Sensors are available in seven force ranges divided into five frame sizes MBO5 MB11 25 MB33 and 41 MBO5 MB11 MB25 and MB33 utilize a torsion bar for both Pivot Point and load resistance Because of the greater forces involved MB41 utilizes a conventional resistance spring type construction rather than the torsion bar 5 MB11 MB25 and MB33 Pillow Sensor Force applied perpendicular to the Load Plate causes the plate Block Roll to rotate about the Pivot Point See Figure 1 This movement causes a change in the position of the Core within the coil of the LVDT Linear Variable Differential Transformer The coil is excited by input voltage from the Tension Controller or Tension Meter Its output varies directly with any change in Core position Movement of the Load Plate is opposed by a torsion bar which also forms the Pivot Point Coil FIGURE 1 MB41 Pillow Force applied perpendicular to the Load Plate causes the plate to rotate about the Pivot Point See Figure 2 This movement causes a change in th
7. e position of the Core within the coil of the LVDT Linear Variable Differential Transformer The coil is excited by the input voltage from the Tension Controller or Tension Meter Its output varies as the position of the Core changes The movement of the Load Plate is opposed by the Main Spring which is connected to the Load Plate by the Transmission Plate Transmission Plate Main Spring FIGURE 2 FORM NO L 20127 H 0109 1 INSTALLATION MB TENSION SENSOR LOCATION Figure illustrates correct MB Tension Sensor location for winding or unwinding control One transport roll A located between the MB Tension Sensors and roll stand serves to fix the web angle over the Sensor Roll Figure 4 illustrates angular changes as the roll changes diameter during processing if roll A is not used These angular changes will cause incorrect readings from the MB Tension Sensors and must be avoided by use of roll A See Figure 3 Figure 5 illustrates a common mistake in MB Tension Sensor mounting In this configuration the S Wrap Drive will effectively isolate tension into two zones T and T A nip roll at the same position would provide the same isolation The roll stand brake or clutch can only control tension in the T zone Since the MB Tension Sensors are mounted in the T zone they cannot sense any tension changes caused by the roll stand and can not be used for closed loop control The MB Tension Sensors must be moved to position A f
8. hall Nexen be liable for any amount of damages in excess of amounts paid by Buyer for Products or services as to which a breach of contract has been determined to exist The parties expressly agree that the price for the Products and the services was determined in consideration of the limitation on damages set forth herein and such limitation has been specifically bargained for and constitutes an agreed allocation of risk which shall survive the determination of any court of competent jurisdiction that any remedy herein fails of its essential purpose Limitation of Damages In no event shall Nexen be liable for any consequential indirect incidental or special damages of any nature whatsoever including without limitation lost profits arising from the sale or use of the Products Warranty Claim Procedures To make a claim under this warranty the claimant must give written notice of the alleged defect to whom the Product was purchased from and deliver the Product to same within one year of the date on which the alleged defect first became apparent ne gt lt en Nexen Group Inc 800 843 7445 560 Oak Grove Parkway Fax 651 286 1099 Vadnais Heights MN 55127 www nexengroup com ISO 9001 Certified 10 FORM NO L 20127 H 0109
9. n the specifications section See Page 9 The selected sensor must be able to tolerate both the load F or F and the tare roll and bearing weight applied to it Total TARE W 2xB DAL eu TARE per Sensor MB Tension Sensors 5 MB11 and MB25 may also be mounted with Reverse Wrap the resultant force away from the MB Tension Sensor See Figures 11 and 12 Web may travel in either direction NOTE Due to the high forces generated by webs needing MB Tension Sensors MB33 and MB44 Reverse Wrap is not recommended continued FORM NO L 20127 H 0109 WEB FORCES continued SYMMETRICAL WRAP See Figure 11 When angle X angle Y or X Y the web angle is symmetrical The resultant for F or will act into or away from the top plate or MB Tension Sensor at 90 In this condition F or can be determined by the formula For Normal Wrap Where Resultant Force T Web Tension F 2T cos X For Reverse Wrap Where F Resultant Force Web Tension F 2T cos X ASYMMETRICAL WRAP See Figure 12 When angle A is less than angle B or angle A is less than B the web angle is asymmetrical The force acting perpendicular to the top plate can be computed from the following formulae Wrap Angles Check appropriate boxes Angle a 90 Angle Aor A Angle Bor Angle A or A D If
10. oduct b the alleged defect is not attributable to normal wear and tear c the Product has not been altered misused or used for purposes other than those for which it was intended and d Buyer has given written notice of the alleged defect to Nexen and delivered the allegedly defective Product to Nexen within one year of the date of shipment Exclusive Remedy The exclusive remedy of the Buyer for any breach of the warranties set out above will be at the sole discretion of Nexen a repair or replacement with new serviceably used or reconditioned Product or issuance of credit in the amount of the purchase price paid to Nexen by the Buyer for the Products Limitation of Nexen s Liability TO THE EXTENT PERMITTED BY LAW NEXEN SHALL HAVE NO LIABILITY TO BUYER OR ANY OTHER PERSON FOR INCIDENTAL DAMAGES SPECIAL DAMAGES CONSEQUENTIAL DAMAGES OR OTHER DAMAGES OF ANY KIND OR NATURE WHATSOEVER WHETHER ARISING OUT OF BREACH OF WARRANTY OR OTHER BREACH OF CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE EVEN IF NEXEN SHALL HAVE BEEN ADVISED OF THE POSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE For all of the purposes hereof the term consequential damages shall include lost profits penalties delay images liquidated damages or other damages and liabilities which Buyer shall be obligated to pay or which Buyer may incur based upon related to or arising out of its contracts with its customers or other third parties In no event s
11. or proper control of the roll stand and T tension MB TENSION SENSOR MOUNTING Mounting dimensions for the four frame sizes are given in MOUNTING DIMENSIONS Pages 8 10 See Figures 13 17 MB Tension Sensors MBO5 MB11 and MB25 may be mounted at any angle See Figure 6 MB33 and MB41 should be mounted to a rigid horizontal or near horizontal surface All MB Tension Sensors must be mounted according to the following guidelines Flatness must be 0 002 0 05 mm over the length of the MB Tension Sensor This can be achieved by milling of the mounting surface NOTE Any shimming required for Sensor Roll leveling must be done between the MB Tension Sensor and pillow block Never shim between the MB Tension Sensor and MB Tension Sensor mounting surface FIGURE 3 FIGURE 4 FIGURE 5 FIGURE 6 continued Sensors Sensors Sensors FORM NO L 20127 H 0109 INSTALLATION continued e Sensor Roll span must equal sensor span This is achieved by securing the MB Tension Sensor to the mounting surface then the Pillow Block Bearings to the MB Tension Sensors and finally the bearings to the Sensor Roll shaft See Figure 7 When Tension Sensors are mounted to a base of material different than that of the Sensor Roll aluminum roll steel mounting base secure only one Pillow Block Bearing to the roll shaft This will allow for different rates of thermal expansion See Figure 7
12. re 10 The upper line indicates minimum acceptable balance specification The lower line indicates practical balance limits balance to closer tolerances is not cost effective SIZING SENSORS MB Tension Sensors are sized reference to two forces The force exerted on the sensor by the web calculated as F or F See Page 5 This force is divided by the number of support points which is normally two for the Sensor Roll In cases of narrow web or wire being detected by a pulley or narrow roll entirely supported by one MB Tension Sensor there is only one support TARE FORCES Weight of Sensing Roll W Weight of Bearing B WEB FORCES Web angle is the angle between the plane of the web as it ap proaches the Sensor Roll and the plane of the web as it leaves X Y or X See Figure 11 A B or A See Figure 12 Maximum web angle is 150 minimum web angle is 0 All MB Tension Sensors may be mounted with the web angle in the Normal Wrap direction i e the resultant force F is toward the MB Tension Sensors See Figures 11 and 12 per Lb of Rotating Mass N 8 2 8 a o o FIGURE 10 The other force to be considered is the weight of the roll and bear ings Both of these forces should be compared to the permissible ranges as stated i
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