User Manual
Contents
1. 1 2 3 2 1 0 9 When It 0 5 second total integral I E A0 5 is as follows I To 5 E T1 E T1 5 E T2 E T2 5 E T3 E T3 5 E T4 E T4 5 E T5 E T5 5 E T6 E 0 5 1 15 2 25 3 25 2 1 5 1 0 5 0 18 Integral computation substitutes maximum error value Description Integral is computed by substituting the error When the error is greater integral may be continuously substituted until an excessive value is accumulated This parameter is adopted to place an upper limit on substitution error in order to prevent this situation from happening Range 0 1 999 9 Factory setting 10 0 Error correction percentage adjustment P correction Description Basic percentage adjustment varies depending on the variation of error The greater the setting is the percentage relationship of greater percentage correction is obtained Range 0 99 99 Factory setting 0 Example P is used to directly correct error deviation It also serves to inhibit excessive integral Excessively great setting will result in vibration Integral control output equation P PK X E error Percentage control output value percentage setting augmentation constant x difference between setting and current value Error 500 CH 3F 2 5V 5V Correction Different output values corresponding to different PK percentage setting augmentation constants DK differential setting D correction Description Differential control2. augmentation constant Differential control is added to reduce the control system s overshoot Brake is applied to differential control in order for the control system to slow down before reaching the ideal position D differential control output value DK integral control augmentation constant x AE At rate of change of error Range 0 99 99 Factory setting 0 Integral control output equation D DK AE At Differential control output value Differential augmentation Rate of change of error Differential control is based on the variation within differential sampling time At to turn AE At into output value Example DK 1 00 D 2 when T2 2 1 x 1 00 2 AE 2 Decline percentage of differential per 0 1 second Description The correction method of differential is of pulse type Therefore when error 16 Cn 3513 stops changing correction declines This parameter sets the rate of decline When the setting is large the decline is slow while when the setting is small the decline is fast Range 0 1 0 99 Factory setting 0 50 Source of tension feedback Description 0 LOAD CELL 1 AI1 Range 0 1 Factory setting 0 Source of basic torque settin Description O Pr 07 1 Control panel knob Range 0 1 Factory setting 0 Display of the lower row Description This parameter is used to display the value to be observed Settings of the parameter are listed below Range 0 2 Factory se
3. illustration below fastening end A weight 3 TC 608P may obtain feedback solely from LOAD CELL AI1 without having to refer to master speed signal AI2 before conducting tension control If above control methods are needed adjust Pr 27 initiating integral correction minimum master speed voltage to 10V 4 If contacts 16 VOUT analog output and 17 VCOM analog output voltage output move in opposite directions such as material tension becomes larger or smaller please check the setting for Pr 22 setting roll up put in is correct 17 Troubleshooting 1 TC 608P cannot calculate a Please check RUN to see if it is lit If RUN flashes please check contacts 18 IP1 initiating contact and 22 ICOM control contact common contact to see whether they are short circuited b Please check LOAD CELL feedback to see whether there is voltage input If there is no voltage input please check loudspeaker and LOAD CELL to see whether output is normal c Please check Pr 21 voltage value to see whether the setting is so small that 24 Cn 312 output voltage is limited to the extent that it cannot reach the output voltage needed 25
4. input detects acceleration tension output will compensate for acceleration augmentation Range 0 255 9 6 Factory setting 20 96 Pr Jaxis acceleration augmentation delay time Description Once axis acceleration is over delay time of acceleration augmentation may be set by this parameter Range 0 25 5 seconds Factory setting 0 5 seconds Pr D axis deceleration augmentation 9 6 Description When AI2 axis speed input detects deceleration tension output will compensate for deceleration augmentation Range 0 255 9 6 Factory setting 20 96 Pr D axis deceleration augmentation delay time Description When axis deceleration is over delay time of deceleration augmentation may be set by this parameter Range 0 25 5 seconds Factory setting 0 5 seconds Pr M Terminating augmentation 9 6 Description When INP1 operation is OFF tension output will compensate for the termination Range 0 255 9 6 Factory setting 20 Pr Db Terminatin movement time Description When INP1 is OFF tension terminates augmentation compensation time The time begins from the moment INP1 is OFF Range 0 25 5 seconds Factory setting 0 5 seconds G1 contact augmentation value Description When INP3 G1 compensation setting is ON tension output will compensate G1 augmentation The value is fixed at adding 9o augmentation Range 0 255 9 6 Factory setting 20 Gi augmentation de
5. segment 1 will be set at a greater rate slower compensation while segment 2 set at a small rate faster compensation Pr 30 is then used to determine the division point which can achieve the effect of faster and steadier revision Range 0 01 99 99 seconds Factory setting 1 00 seconds The margin of error when using segment 1 integral I revision Description This value is the margin of error when using segment 1 Use segment 1 when smaller than the margin of error while using segment 2 when greater than the margin of error Range 0 1 999 9 Factory setting 1 00 Integral control output equation I gt EA It1 Integral control output Total of past errors Example When integral control time constant A It1 is set at a greater value within a fixed period of time T the accumulated I value is smaller and the output effect caused by I value is smaller too By the same token When integral control time constant A It1 is set at a smaller value within a fixed period of time T the accumulated I value is greater and the output effect caused by I value is greater too Example For an error response curve as shown below when the error goes from 0 to 3 and back to 0 the integral value obtained varies due to different It settings E Error value ww Error value curve T T2 T3 T4 T5 T6 Sec Time When It 1 second total integral I gt E A1 is as follows I Ti E T2 E T3 E T4 E T E T E
6. with magnetic powder brake controlling axis s torque to be used in roll up 7 Motor driver A Use TC 608P analog output contact and roll up speed differential of roll up axis s motor to achieve material surface tension control to be used in roll up B Use TC 608P analog output contact and roll up speed differential of put in axis s to achieve material surface tension control to be used in power put in 16 Issues Needing Attention When Conducting Trials 1 Please check wiring and parameter settings to make sure they are correct 2 Calibrating and zeroing tension A Zeroing tension After power is turned on under the circumstance of zero load check to see whether reading of controller s upper row displays zero If tension displays please adjust Pr 23 to ZERO until reading displays zero B Calibrating tension After tension is zeroed please set Pr 24 number of kilos corresponding to 10V to total weight of LOAD CELL Take a weight 23 Cn 3513 suggested weight is 1 2 or 1 5 of total weight of LOAD CELL Fasten it with a rope Pass the rope through simulation material s actual route Fasten front end of weight to front end of LOAD CELL Allow back end of LOAD CELL to droop in order to create tension Check to see value displayed on upper row of controller is the weight of the weight If the value is different from tension displayed please adjust SPAN of Pr 24 until displayed value is the same as the weight s weight See
7. PAN Description When tension feedback reading is different the actual weight this parameter may be used to adjust the rate When using zero shall be adjusted before adjusting rate Range 0 001 9 999 Factory setting 1 000 Position of tension decimal point Description This is used to set the position of tension display s decimal point Range 0 3 Factory setting 1 Pr 26 pis laying average frequenc Description When tension displays this parameter can be used to set average frequency in order to obtain more stable readings Range 1 255 Factory setting 1 Starting the minimum master speed voltage value of integral Description When master speed AI2 voltage is smaller than the setting integral terminates If integral is set at 0 it continues after startup Otherwise master speed is set at 0 Range 0 10 00 V Factory setting 0 05 V Segment 1 integral compensation rate I1t segment 1 integral compensation time Description When error continues to be generated this value can be used to set integral rate The greater the value of setting is the slower the speed of compensation and vice versa Excessively small setting will lead to output vibration 13 Range 0 01 99 99 seconds Factory setting 5 00 seconds Segment 2 integral compensation rate I2t segment 1 integral compensation time Description Integral can be computed in two steps The parameter is segment 2 value When using
8. Tension Controller Feedback System TC 608P Control Panel In the Form of a Load Cell Built In communications Function User Manual RAS KX nr TENSION CONTROLLER Nw NS XQ SAAT ATE NONE NE D AS SS itis QQ RUN SUN SSS OUT XXL XEN SE SSMNAMAMA QW ERR SSSNSN XX RL CATCH A NIK NS SS NN SNR LL on IIIIKIIQ NIV SSNNNY NIIKNKNKNKNKNKNKNWS gt LINK A TC 608P NIK OS Six MWA AY dE E x 10 11 12 13 14 15 16 17 Contents Foreword Attention TC 608P Principles TC 608P Features Working Diagram i Put In ii Roll Up Inspection of products i Exterior ii External Dimensions iii Control Panel Display and Operating Directions 1 LED 2 Touch Key Operating TC 608P Installing i Standard Specifications ii Fastening Side of Controller Terminal Connection and Control Panel Installing Dimensions Wiring i Terminal Functions ii Terminal Connections Parameters List of Parameters List of Communication Parameters Indicating Output Status Feedback Equipment Control Equipment Issues Needing Attention When Conducting Trials Troubleshooting 1 4 Ch 515 Foreword Many thanks for choosing TC 608P Feedback System Tension Controller hereinafter referred to as 608P Read this user manual before using to take full advantage of 608P and for users safety The manual tells you how to do the wiring set parameter
9. ck lower limit insensitive area basic torque voltage reversion initiate augmentation initiation time axis acceleration augmentation master speed acceleration termination delay X 0 1 second axis deceleration augmentation master speed deceleration termination delay X 0 1 second terminate augmentation termination time G1 contact augmentation value G1 contact movement termination delay time G2 contact augmentation value G2 contact movement termination delay time minimum output torque voltage maximum output torque voltage 21 13 Indicating Output Status Machine operating ir Initiation Axis speed Initiation time Termination time Acceleration augmentation Deceleration augmentation Nu Initiation Enduranc Put in output Initiati n output i i i Endurance Roll up output ON Acceleration Deceleration NER eee Acceleration A F1 i i D Acceleratiueleration EE um Acceleratiureleration ri Deceleration Deceleration OFF Termination x Time Termination Endurance Time Termination Endurance Time Initiation Use Pr 8 to set initiation augmentation percentage and Pr 9 to set initiation augmentation time Compensation direction will change depending on put in or roll up Termination Use Pr 14 to set correction compensation percentage and Pr 15 to set correction compensation time Compensation direction will change depending on put in or
10. d 18 INP1 External input contact 1 Operating started 19 INP2 External input contact 2 Tension reversion manual automatic 20 INP3 External input contact 3 G1 plus 9o compensation 21 INPA External input contact 4 G2 minus 9o compensation 22 ICOM Input contact COM Digital input contact COMMON 23 485 RS 485 RS 485 communication 24 485 RS 485 RS 485 communication Attention Input contact is a dry contact or NPN contact Configuration of terminals Wiring of terminals master speed analog output input ae analog input communication connection ry _ Y variable resistor or external analog m signals 2 NS N n roll up put in motors 4 hi en master SL motor no c UZ LA Cylinder electro pneumatic transducer A magnetic magnetic particle brake E clutch river tension feedback signals 10 Parameters Setting password Description Parameter password The setting needs to be the same as 1234 before other parameters can be set Range 0 9999 Factory setting 1234 Setting maximum value Description Setting the maximum value when adjusting tension setting on control panel lower row Range 0 1 999 9 Factory setting 100 0 Setting minimum value Description Setting the minimum value when adjusting tension setting on control panel lower row Range 0 1 999 9 Factory setting 100 CH 3Fr Feedback upper limit Description When the feedbac
11. e value 28 Segment 1 integral 00 01 99 99 seconds 15 00 compensation rate 29 Segment 2 integral 00 01 99 99 seconds 11 00 compensation rate 30 Error scope of use of segment 000 1 999 9 1 00 1 integral 31 Integral computation 000 1 999 9 10 0 substitution maximum error value 32 Error correction percentage 000 0 99 99 000 adjustment value 33 DK differential setting 000 0 99 99 000 34 Decline percentage of 000 1 00 99 0 50 differential per 0 1 second 35 Source of tension feedback 0000 0001 000 36 Initiate source of voltage 0000 0001 000 setting 37 Display method of lower row 10000 0002 000 38 MODBUS communication 0001 0255 001 20 address 39 Communication rate 0001 0005 004 40 MODBUS communication 0000 0002 000 format 41 RELAY 1 designated output 0001 0004 002 method 42 RELAY 2 designated output 0001 0004 003 method 43 Select scope of output voltage 0000 0001 000 12 List of Communication Parameters MODBUS communication description 0000 0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 0012 0013 0014 0015 0016 0017 0018 0019 0020 0021 0022 0023 tension display value output voltage value error code tension setting Set maximum value Set minimum value feedback upper limit feedba
12. evised and specified through communication Standard Panel dimensions 96mmx96mm Dimensions Opening dimensions 92mmx92mm Installation depth 150mm Weight 1kg and under Use Environment for Installation Environment Site of use Indoors no corrosive gases fluids and dust Operating temperature OC to 60 C Storing temperature OC to 60 C Humidity of surrounding 9096 RH and under environment 9 Wiring M Terminal code numbers and pins Serial Name Function Description 1 AC1 AC 220V Power input 10 error 2 AC2 AC 220V Power input 10 error 3 FG FG Power grounding 4 V LOAD CELL 10V Connect LOAD CELL reference power supply input 5 V LOAD CELL OV Connect LOAD CELL reference power supply input 6 S LOAD CELL signal Connect LAOD CELL signal output 7 S LOAD CELL signal Connect LAOD CELL signal output 8 RY1C Relay1 COM contact CH 3Fr Serial Name Function Description 9 RY1A Relay1 A contact Parameter designation 5A AC250 DC35V 10 RY2C Relay2 COM contact 11 RY2A Relay2 A contact Parameter designation 5A AC250 DC35V 12 AI 1 Analog input 0 10V Analog external feedback input 13 AI2 Analog input 0 10V Master speed input 14 ACOM ACOM Analog COMMON contact 15 12V DC 12V Use of 12V power output analog setting 16 AOUT1 Analog output 1 Analog command output 0 10V 17 AOUT2 Reserve
13. ing preset and actual tension values possess the features of accelerating and decelerating master speed and augmentative delayed time output parameter power outage memory function able to initiate augmentative function able to compensate static friction arising from initiating machine tension reduction function at shutdown eliminates excessive tension 5 Working Diagram Put in Motor A A Air i Magnetic i Pressure Powder Load cell Brake Brake INV E P VA 816 Electro Pneumatic INV TC 608P Roll up Load cell INV INV Do Driver m A A A T TC 608P Oil Pressure Motor Driver c 2 m 212 6 Inspection of Products Exterior Dimensions d gt i H J d gt p QO MODE Y sr DA TC s08P Y y Back Panel Pins Pins 12 24 Back Cover Pins 1 3 Pins 4 11 Casing Dimensions 96mm X 96 mm Opening Dimensions 92 mm X 92 mm M Control Panel and Operating Directions Operating Status Relay Output Abnormal Status Tracking Complete Manual VR Knob WB LED Signals 2 RUN OUT ERR CATCH Y TENSION CONTROLLER Tension Display Setting Display 1MODE A y SET i z BLINK Communication TC 608P Status Change Set Parameter Decrease parameter Increase Upper row LED display Specifies display of feedback value or output percentage through parameter 18 while the display is in regular display mode Lo
14. k is greater than the setting a feedback upper limit will be set which can be used in conjunction with RELAY output Range 0 999 9 Factory setting 90 0 Feedback lower limit Description When the feedback is greater than the setting a feedback lower limit will be set which can be used in conjunction with RELAY output Range 100 0 999 9 Factory setting 0 1 Insensitive area Description When the error between the feedback and the setting falls below the parameter s setting corrective computation will terminate in order to avoid the instability caused by a minor error Range 0 25 5 Factory setting 0 3 B PrO7 jutvoltage Description When input contact INP2 is ON tension output will revert to basic torque output If Pr 36 source of basic torque is set at 0 designated by Pr 07 the parameter is able to set basic torque output value Range 0 10 00 V Factory setting 1 00 V Pr 0B Startu augmentation Description When INP1 operation is started tension output will compensate startup augmentation first with compensation time set by Pr 09 Range 0 255 Factory setting 20 Pr 09 Startup time Description When INP1 operation is started tension starts augmentation compensation time value Computation begins from the instant INP1 is ON Range 0 25 5 seconds Factory setting 0 5 seconds CH 2Fr Pr axis acceleration augmentation 9 6 Description When AI2 axis speed
15. lay time Description When INP3 G1 is OFF this parameter is able to set delay termination compensation time Range 0 25 5 seconds Factory setting 0 5 seconds Pr B jc contact augmentation value 9 o Description When INP4 G2 compensation setting is ON tension output will compensate for G2 augmentation This value is fixed at deducting 9o augmentation Range 0 255 9 6 Factory setting 20 Pr B jc augmentation delay time Description When INP4 G2 is OFF this parameter is able to set delay termination compensation time Range 0 25 5 seconds Factory setting 0 5 seconds Pr 20 jou ut minimum torque voltage Description Regardless of the results of output computation output shall not fall below this preset voltage Range 0 10 00 V Factory setting 1 00 V Pr 20 jou ut maximum torque voltage Description Regardless of the results of output computation output shall not exceed this preset voltage Range 0 10 00 V Factory setting 10 00 V Selecting work mode Description Compensation direction varies as different work modes are selected 0 Put in 1 Roll up Range 0 1 Factory setting 0 cn 5sT Feedback zero drift correcting ZERO Description When tension feedback reading zero is different the actual this parameter may be used to move zero position forward and backward Range 9999 9999 Factory setting 0 Adjusting feedback rate correcting rate S
16. lue 000 1 999 9 100 4 Feedback upper limit 0000 999 9 90 0 5 Feedback lower limit 100 0 999 9 00 1 6 Insensitive area 000 0 025 5 00 3 7 Basic output voltage 00 00 10 00 V 1 00 8 Initiate augmentation 0000 0255 020 9 Initiate delay time 000 0 025 5 seconds 00 5 10 Correct percentage when 0000 0255 020 master speed increases 11 Correct delay time when 000 0 025 5 seconds 00 5 master speed increases 12 Correct percentage when 0000 0255 020 master speed decreases 13 Correct delay time when 000 0 025 5 seconds 00 5 master speed decreases 14 Master speed stop correction 0000 0255 020 percentage 15 Master speed stop correction 000 0 025 5 seconds 100 5 delay time 16 G1 contact augmentation 0000 0255 020 value 19 17 G1 augmentation delay time 000 0 025 5 seconds 100 5 18 G2 contact augmentation 0000 0255 020 value 19 G2 augmentation delay time 000 0 025 5 seconds 100 5 20 Minimum output voltage 00 00 10 00 V 1 00 21 Maximum output voltage limit 00 00 10 00 V 10 00 22 Set roll up put in 0000 0001 000 23 Feedback zero deviation 9999 9999 000 Serial Parameter Scope User Settings Note 24 Feedback value rate 0 001 9 999 1 000 adjustment 25 Tension decimal point 0000 0003 001 26 Tension average time 0001 0255 001 27 Initiate integral s minimum 0000 10 00 V 00 5 master speed voltag
17. roll up Acceleration Use Pr 10 to set acceleration augmentation percentage and Pr 11 to set acceleration augmentation time Compensation direction will change depending on put in or roll up Deceleration Use Pr 12 to set deceleration augmentation percentage and Pr 13 to set deceleration augmentation time Compensation direction will change depending on put in or roll up 22 Cn 3513 14 Feedback Equipment 1 LOAD CELL LOAD CELL detects material surface tension and relay signal to controller for calculation 2 Dancer Dancer detects position of roller or arm and relay signal to controller for calculation in order to control material tension 3 Frequency converter TC 608H may connect master motor frequency converter 0 10VDC output into master speed signal AI2 in order to determine master acceleration deceleration or stop and assist in controlling material tension 15 Control Equipment 4 Magnetic powder brake TC 608P analog output contact can be used to control put in axis s torque in order to achieve material surface tension control to be used in passive put in 5 Electro pneumatic converter Use cylinder to control put in axis s torque through TC 608P analog output contact in order to achieve material surface tension control to be used in passive put in 6 Magnetic powder clutch Through TC 608P analog output contact speed may be fixed using roll up axis s motor Material surface tension control can be achieved
18. s and detect abnormalities and deal with them Keep the manual for future reference Contact us in the event of questions to which answers cannot be found in the manual We will do our utmost to offer you satisfactory solutions Your comments are welcome anytime Attention No wiring and removing installing connector of 608P when the power is on Terminals of 608P are contacts of feedback and output signals Do not use them for other purposes Do not connect the output terminal of 608P to AC power or allow alien voltage to enter Do not remove the casing and conduct pressure endurance tests on components Make sure the power input into terminals 1 and 2 to be AC 220V 10 Principles The controller sets the material put in and roll up and the tension value required according to the actual production conditions 608H adjusts the output command after comparing the settings with the value detected and returned by the Load Cell in order to change the braking force or the roll up torque automatically setting the actual tension to the preset tension a high precision tension control system Features high precision high reliability tension value may be set at kg N LB by the user may be directly connected to LOAD CELL for input digitized zeroing and rate adjustment features for ease of operation digital design unchanged characteristic humanistic design easy to operate output command multi functional display includ
19. ter display mode A gt may be used to add one to parameter number After entry into parameter change mode A may be used on Lower row Display Flash to add one to parameter value 4 Ww When in parameter display mode lt W gt may be used to deduct one from parameter number When in parameter change mode lt W gt may be used on Lower row Display Flash gt to deduct one from parameter value Operating TC 608H Enter corresponding values used by the system s Load Cell into internal parameters of 608H see Parameters for details Press or V on the control panel and enter the tension value needed Or set to Manual and use the control panel knob to enter the tension needed See Terminals and Parameters for applicable contacts functions and parameters 8 Electric Dimensions and Use Environment for Installation Electric Dimensions and Standard Dimensions Voltage AC 220 V 10 50 60HZ 1 set of LOAD CELL input 0 4 mV input floating zeroing and magnifying Electric 2 sets of AI optional DC 0 10V input 12 bit resolution input Dimensions impedance 200K 1 set of AO 1 set optional DC 0 10V output max 10mA 12 bit resolution 4 sets of DI Dry contact or crystal method mode Low Active 2 sets of RELAY DO Relay A contact 5A 250VAC 30VDC RS 485 MODBUS Communication adopts RS 485 interface communication MODBUS RTU protocol output and read may optional be activated r
20. tting 0 Setting Display 0 Tension setting 1 Output value 2 Master speed voltage Pr 38 30 MODBUS designated communication station number Description When using the communication feature of MODBUS an one and only station number for the machine can be set in order to distinguish between different controllers Range 1 255 Factory setting 1 Pr 39 MODBUS communication rate Description When using communication a certain rate can be designated as follows 1 2400 2 4800 3 9600 4 19200 5 38400 Range 1 5 Factory setting 4 Pr M MODBUS communication format Description When using communication the format may be designated as follows 0 N 8 2 1 E81 2 N 8 1 Range 0 2 Factory setting 0 Pr 4 RELAY1 output designation Description RELAY1 may designate the output method 1 Start 2 Feedback HI 3 Feedback LOW 4 Feedback NORMAL Range 1 4 Factory setting 2 Pr 42 RELAY2 output designation Description RELAY1 may designate the output method 1 Start 2 Feedback HI 3 Feedback LOW 4 Feedback NORMAL Range 1 4 Factory setting 3 Selecting range of output voltage Description 0 0 10V 1 0 5V Range 0 1 Factory setting 0 11 List of Parameters Serial Parameter Scope User Settings Note 1 Set password 0000 9999 1234 2 Set maximum value 000 1 999 9 100 0 3 Set minimum va
21. wer row LED display Displays tension setting while the display is in regular display mode RUN When the controller stops working RUN goes off When the controller begins working RUN continues outputting OUT When relaying output CATCH When the INDEX feature is turned on if INDEX error is within preset range Pr 02 this light is lit to indicate completion of tracking ERR When the system detects abnormalities this light is lit LINK Optional When RS 485 has external connection each time a communication is completed LINK flashes one time E Setting Parameters Using press keys po a JL v 1 MODE The key is used to enter parameter display mode or return to regular display mode Press once to enter parameter display mode Press again to return to regular display mode When inputting parameters the Pr XX displayed at the bottom is parameter number while the content of the parameter is displayed at the top 2 SET This key serves three purposes When pressing MODE and SET the Pr XX displayed at the bottom begins flashing indicating entry into parameter change mode After parameter change is completed press SET to store changed value in the controller If SET is not pressed before pressing MODE to exit the parameter will remain unchanged When in regular display mode SET may be used to remove error status 3 lt A gt After entry into parame
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