Open Loop Tension Controller
Contents
1. FIGURE 10D FORM NO L 20348 F 0705 10 GLOSSARY OF TERMS Sonic Prox Prox Encod Counts Full Roll Setpoint Hold Torque Strt Time Taper Stop Mult Stop Time Diam Hyst Idiam Thick Min Dia Alrm Min Alarm NC NO Min Out Max dia Alrm Max Alarm NC NO Accept Changes Y N Ultrasonic Sensor Proximity Sensor Proximity Sensor Encoder combination For Prox encoder combination only counts represent the number of pulses generated by the encoder dur ing 100 inches of web travel Diameter of the largest roll used within the range of O to 70 inches 0 to 1778 mm Percentage of controlled output applied to the brake clutch or drive at full roll diameter Setpoint adjust ment range is 0 to 100 Percentage of controlled output used in several different ways For Unwind applications when the web is not moving it is used to apply a constant output which holds the roll stationary and prevents slack webs At the beginning of a run Hold Torque is maintained for the duration of Start Time enabling the process to have a lower brake torque as the roll is accelerating For Wind applications Hold Torque provides suf ficient torque during Start Time to enable the winding process to begin Hold Torque adjustment range is O to 100 Start Time During Start Time the TCD 600 s output is determined by the Hold Torque Value This value is maintained for the duration of the Start Time period enabling the2. WINDING APPLICATION NOTE For winding applications that use a mechanical clutch the minimum output level can be set to overcome the me chanical characteristics of the clutch e g a release spring See Calibration Mode CAL MIN OUT for the set up procedure Otherwise the minimum output level should be set to zero for instances when a mechanical clutch is not used When the Start contact is closed or the Start button is momentarily pressed the TCD 600 goes into Start operation for the duration of the Start Time see figure 40 The output level changes to the Hold Torque value that was set as one of the Job parameters The clutch begins to rotate and take up slack from the web The machine begins to accelerate After the Start Time has expired the TCD 600 will enter Automatic operation and output will increase steadily as a function of the roll s diameter and Setpoint and Taper setting if required As the roll winds output level will increase in order to maintain constant tension If taper tension is needed rather than constant tension use the Taper Tension setting to decrease the tension as the roll increases in diameter See Overview in OPERATION section for a description of Taper Tension Whenever the Hold Resume 22 Start Contact fe ux copo Hold Resume Contact Sis N MEE Stop Contact EE IE 1 Hold Torgue 2 Start Time 3 Automatic Operation 4 Hold Operation 5 Stop Operation 6 Stop Time FIGURE 39 UNWIN
3. Job Mode Calibration Mode NOTE Diameter calibration for the ultrasonic sensor is only required for the initial setup of the machine or if the ultrasonic sensor has been moved To gain access to Machine setup and diameter calibra tion press the Nexen logo button while simultaneously pressing the STOP button and hold them until SETUP ENABLE appears on the display See Figure 11 1 Using the Select Upper button advance the top line of the display to Calibration Mode See Figure 26 Using the plus or minus buttons select Edit then press the Enter but ton 2 Diam will appear in the display See Figure 27 Press Enter NOTE The following procedure Steps 3 6 applies only to the Ultrasonic Sensor Advance to Step 7 to calibrate a Proximity Switch Sensor or Proximity Switch Encoder sensors 3 Slide an empty core onto the roll shaft so it is seen by the Ultrasonic Sensor 4 CAL DIAMETER Core Diam will appear in the display See Figure 28 Using the plus or minus button enter de sired core diameter then press the Enter button Comput ing will appear in the display for a few seconds then the display will advance to the next step See Figure 29 5 Remove empty core slide on a maximum diameter roll so it is seen by the Ultrasonic Sensor Rolls of less than the maximum diameter can be used In these instances enter the actual diameter when prompted for Max Diam 6 CAL DIAMETER Max Diam will appear in th
4. O VDC corresponds to the roll core and 5 VDC corresponds to a maximum diameter roll In addition two contact outputs are available for use as user specified minimum and maximum roll diameter alarm outputs FORM NO L 20348 F 0705 TCD 600 Output to brake for Unwind applications or to clutch for Wind applications FIGURE 1 ULTRASONIC SENSOR FIGURE 2 TARGET PROXIMITY SWITCH FIGURE 3 OPTICAL ENCODER TARGET PROXIMITY SWITCH FIGURE 4 INSTALLATION CONTROLLER POSITIONING The TCD 600 Controller should be mounted in a location that will allow convenient use for the operator CAUTION The TCD 600 is an electronic component and should be mounted in a shock and vibration free area which has an ambient temperature of less than 120 F 50 C and more than 32 F 0 C PANEL DIMENSIONS AND 7251 n MOUNTING INSTRUCTIONS 13 mm Use mm 7 56 In I CN 192 mm CONTROL PANEL 7 28 In PANEL MOUNTING INSTRUCTIONS 185 mm D Remove the Retaining Screw with a 1 16 Allen wrench a Pull the Slide Bars on both sides off the Case PANEL CUTOUT Q Slide the Case th h the cutout in th trol l gt ide the Case throu e cutout in the control panel Dimensions a Os Push the Slide Bars back into the grooves of the Case Reinstall the Retaining Screws and tighte
5. Prox Encod Sensors Only 00833 100 in Wind Applications Sonic Sensor Edit Job Parameters Full Roll 060 00 in Setpoint 010 0 Hold Torque 010 0 Strt Time 003 0 sec Taper 000 0 Diam Hyst 0 10 in Min Dia Alrm 006 00 Min Alarm NC Max Dia Alrm 050 00 Max Alarm NC Accept Changes Yes or No Y N Wind Applications Prox Sensor Edit Job Parameters Full Roll 060 00 in Setpoint 010 0 Hold Torque 010 0 Strt Time 003 0 sec Taper 000 0 IDiam 006 00 in Thick 0 0050 in Min Dia Alrm 006 00 Min Alarm NC Max Dia Alrm 050 00 Max Alarm NC Accept Changes Yes or No Y N Additional Languages include Spanish and French other languages may be included later contact Nexen for details Note Refer to Glossary of Terms for explanations of the parameters 17 FORM NO L 20348 F 0705 OUICK REFERENCE SETUP AND CALIBRATION WORKSHEET Wind Applications Prox Encod Sensor Edit Job Parameters DEFAULT JOB 1 JOB 2 JOB 3 JOB 4 JOB 5 Full Roll Setpoint 060 00 in 010 0 Hold Torque 010 0 Strt Time 003 0 sec Taper 000 0 Diam Hyst 010 0 in Min Dia Alrm 006 00 Min Alarm NC Max Dia Alrm 050 00
6. press the Enter button See Figure 21 The display will prompt you to overwrite any previous job you may have entered See Figure 22 Press the plus or minus button to select Y for yes then press Enter and the display will confirm the save See Fig ure 23 ne en EDIT JOB OFF Full Roll 060 00 in e go FIGURE 18 ne gt lt en GEE EON ETRE TCD 600 EDIT JOB OFF Accept Changes Y N a go FIGURE 19 ne gt lt en GEE REN TREE ToD 600 SET JOB OFF Edit Load Save e gR FIGURE 20 ne gt lt en GEE REN TRE TCD 600 SAVE JOB AS Job 1 D FIGURE 21 ne gt lt en Overwrite Y N a2 Job 1 OUTPUT a go FIGURE 22 ne gt lt en CE SON TRE TCD 600 Overwrite Y N Job 1 Saved OUTPUT D FIGURE 23 a go continued FORM NO L 20348 F 0705 14 SETUP PROCEDURE continued 8 The display returns to Set Job Press EDIT again to edit JOB 2 and repeat this procedure up to JOB 5 if needed Or press Load to recall previously saved job settings to use for a job you want to run now Press the plus or minus button to select Load then press Enter See Figure 24 9 You can then choose to load either the default job or any of 5 previously saved jobs Press the plus or minus button to select the desired job See Figure 25 then press Enter the display will confirm that the selected job is loaded then it will return to the Set
7. process to have a lower torque while the roll is accelerating thus providing a smooth startup of the process and preventing web breaks Start Time has an adjustment range of O to over 200 seconds Used only in Wind applications Taper starts the roll at core with a higher tension value then automatically decreases this tension as the roll diameter increases Taper affects the original Setpoint value by gradu ally taking away from the Setpoint a percentage of its value The amount of Taper can be adjusted within a range from O to 86 5 Stop Multiplier During a stop cycle of an Unwind application the current output value is multiplied to produce sufficient torque to completely stop a roll The Stop Multiplier can be adjusted to a value from 1 to 9 9 Stop Time is the length of time that the Stop Multiplier Torque value is applied and can be adjusted from O to over 200 seconds Diameter Hysteresis This feature is used to enable the TCD 600 to ignore the changes in roll radius cre ated by out of round or egg shaped rolls The Diameter Hysteresis can be adjusted from O to 2 55 inches 0 to 25 5 mm Initial Diameter This is used with Proximity Sensor only systems for both Wind and Unwind applications This value is the actual diameter of the roll or core at the start of a job and must be entered to ensure proper operation The value of Idiam can be adjusted from O to 650 inches 0 to 6500 mm Web thickness also used with Proximit
8. value 00833 with your calculated value Example The Nexen Optical Encoder is attached to a 12in 305mm circumference wheel This wheel contacts a roller that is moving at the same speed as the web For every 12 in 305mm of web that passes by the Encoder produces 100 pulses Use the following formula to calculate the new number 100 multiplied by number of pulses per revolution of the encoder divided by the number of inches of web length per revolution of the encoder Example 100 in 2540mm x 100 pulses per rev 12 inches 305mm per rev 00833 Press the plus or minus buttons to change the default value to your calculated value then press Enter The upper display line will now return to the Setup Mode ne gt lt en CREE REN EIE TCD 600 SETUP MODE OFF Job Machine m OUTPUT ale Minus Enter E x Plus FIGURE ne en CRETE GOH pH ToD 600 SET MACHINE OFF Language English B d a a o FIGURE 13 ne en GEE RSH STAI TCD 600 SET MACHINE OFF Millimeters Inches ne en SET MACHINE OFF WIND UNWIND FIGURE 15 ne gt lt en CREE SEN ERES TCD 600 SET MACHINE OFF Sonic Prox Encod a g FIGURE 16 ne gt lt en CREE EET ERLE TCD 600 SET JOB OFF Edit Load Save FIGURE 17 continued 13 FORM NO L 20348 F 0705 SETUP PROCEDURE continued SETUP MODE JOB SETUP 1 Press the minus button to se
9. value that was set as one of the Job parameters The purpose of the Start value and Timer is to keep the brake torque low while the roll accelerates thus preventing the web from being over tensioned during acceleration After the Start Timer has expired the TCD600 enters Automatic Operation The output level is a function of the roll diameter and the setpoint percentage As the roll unwinds the output level will decrease in order to maintain constant tension If the Hold Re sume contact is closed or the Hold Resume button is pressed the output level will remain constant until the contact is opened or the button is released allowing the TCD600 to return to Auto matic Operation When the Stop contact is momentarily closed or the Stop button is pressed the TCD600 s output will increase by the number of times set in Stop Mult as one of the Job parameters This increased level will be maintained for the duration of the Stop Time to provide the additional braking torque needed to decelerate the roll After the expiration of Stop Time the output level will return to the value it had before the stop If the Hold Resume contact is then closed or the Hold Resume button is momentarily pressed the output level will remain at the pre stop value for the duration of the Start Time However if the Start contact is closed or the Start button is momentarily pressed the output level will change to the Hold Torque value for the duration of the Start Time
10. you may want to keep the Output turned Off Also to allow free movement the Output should be Off whenever a roll is being changed The rest of the buttons will be explained in the RUN MODE section of this manual Parameter default settings for Wind and Unwind applications are listed on the Quick Reference Worksheets on Pages 13 15 The Worksheets also provide space for you to write in your own settings this can be useful during Setup The parameters for the Setup and Calibration Modes must be set to the specifications of the job to be run first in Setup Mode enter the Machine parameters next the Job parameters and finally in Calibration Mode enter the Calibration Mode parameters SELECT UPPER BUTTON 2 LINE DISPLAY SELECT LOWER nu nexen DIAMETER TENSION CONTROLLER TCD 600 STANDBY MODE OFF HOLD RESUME Nexen TCD BUTTON OUTPUT BUTTON MINUS LEFT SHIFT PLUS RIGHT SHIFT FIGURE 11 BUTTON BUTTON BUTTON continued FORM NO L 20348 F 0705 12 SETUP PROCEDURE continued SETUP MODE MACHINE SETUP NOTE To gain access to Machine setup press the Nexen logo button while simultaneously pressing the STOP button and hold them until SETUP ENABLE appears on the display 1 Press the Select Upper button until you reach Setup Mode See Figure 12 The parameters in Setup Mode are set when the machine is initially installed or when the machine is modified Press the plus or minus buttons to select Machine
11. 2 F 120 F 0 C 50 C Te DR DU 1 pound 1 6kg Proximity Switch nee 15 VDC NPN Normally Closed Open Collector 40 mA Sink minimum Logic Level VLow lt 1 VDC VHiGH gt 2 25 VDC Minimum Pulse Width 100 Microseconds Encoder sioen tom aa e tener 15 VDC Open Collector Output 12 mA Sink minimum Logic Level VLow lt 1 VDC VHiGH gt 2 25 VDC Minimum Pulse Width 600 Nanoseconds WIthASOMIG SONS od m 24 VDC 0 10 VDC Output PARTS LIST TCD 600 Controller English Spanish nsii een 912123 TCD 600 Controller English French 912145 Ultrasonic Sensoriese ee een catio teer ek era a 912127 Optional Mounting Bracket for TCD 600 ese se ee ee ee ee ee ee Rae gekke Ge eek Ge eek eek eek 912129 ede NE lee ER M 912140 Optional Encoder Mounting Bracket 912141 Proximity dle eec EE EE EE EE OE 912068 SERVICE INSTRUCTIONS The TCD 600 has no field serviceable parts and must be returned to Nexen for repair FORM NO L 20348 F 0705 23 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 FIT NESS 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 N
12. D APPLICATION Output Level Web Speed Start Contact Hold Resume Contact Stop Contact AN ENE y p 1 Minimum Output 2 Hold Torque 3 Start Time 4 Automatic Operation 5 Hold Operation 6 Stop Operation FIGURE 40 WINDING APPLICATION contact is closed or the Hold Resume button pressed the output will remain constant until the Hold Resume contact is opened or the button is released allowing the TCD 600 to return to Automatic Operation This is used when winding is interrupted once or several times per roll winding When the Stop contact is closed or the Stop button is momen tarily pressed the TCD 600 s output will remain constant at its present value The machine is decelerated to a complete stop If the Hold Resume contact is then closed or the Hold Resume button is momentarily pressed the output level will remain at the pre stop value for the duration of the Start Time If the Start contact is closed or the Start button is momentarily pressed the output level will change to the Hold Torque value for the duration of the Start Time FORM NO L 20348 F 0705 SPECIFICATIONS ASA P 115VAC 230VAC 0 3A 0 6A 50 60Hz 1 Phase Torque Control OUEDpUL t een 0 10VDC 10mA 4 20mA 600Q max Diameter Output Ana eek 0 5VDC 10mA NET ASe RE OE Er EA irea 30Volts 100mA optically isolated Switch Inputs Start Stop Hold iade catio en aan 15VDC 1 5mA Ambient Temperature 8
13. Edit Diam Min Out Diam Core Diam 001 00 in Max Diam 060 00 in Min Output 000 0 SETUP MODE Set Job Save SETUP MODE Set Job Load Default Job Note Refer to Glossary of Terms for explanations of the parameters 19 FORM NO L 20348 F 0705 OPERATION OVERVIEW The TCD 600 is an open loop controller that maintains 10096 constant tension by changing its output as the diameter of the roll changes This controlled output can be used for wind or unwind applications The TCD 600 can be used to control air actuated clutches and brakes or as a trim signal to control motor drives The TCD 600 can calculate the roll diameter by using any of three sensor configurations Ultrasonic Proximity or Proximity Encoder O U T P U T 4Z OT mo The TCD 600 s Setpoint determines the amount of output doce panels to be applied to the brake clutch or drive at maximum roll 0 CORE ROLL MAXIMUM es DIAMETER diameter See Figure 33 If the Setpoint is adjusted to maximum 10096 then maximum output will be applied when the roll is at its maximum diameter When the Setpoint is adjusted for less than maximum the output at maximum roll diameter will be proportionately less This Setpoint value can be changed during actual operation by using the plus or minus buttons to increase or decrease the Setpoint to fine tune the tension FIGURE 33 To maintain constant
14. FROM END OF WIRE 1 4 AC Select Switch 115 230 VAC 60 50Hz 30VA Max Mn TE ai E 5 6 7 8 9 101 6 7 8 9 10 11 12 13 14 15 16 17 HUI 22 23 24 25 26 27 28 23 24 25 26 27 28 29 30 31 32 33 3 HUDOBOHTO OUI FIGURE 9 BACK PANEL ELECTRICAL CONNECTIONS continued FORM NO L 20348 F 0705 ELECTRICAL CONNECTIONS continued ELECTRICAL CONNECTIONS TCD 600 Back Panel 115 230 VAC Neutra 230 AC Earth Ground External Power Supply 5 VDC 8l Input for Isolated Control 0 10 VDC f Control Output Signals Output Com Shield 4 20 mA DC Control Output JUUL LG Not Used Red Black To EN40 or EN50 Red 15 VDC To Ultrasonic Red 24 VDC To Nexen Encoder Blac k Common Brown 15 VDC To Proximity Blue Com Brown Signal Sensor Blac k Signal To White Signal Ultrasonic Blac k Com Sensor Shield Shield Not Used 0 5VDC f Roll Diameter Output Not Used 8G LG 96 GG VG EG GG Ll OL 6 8 Minimum Diameter Alarm a Remote Start See Minimum Diameter Alarm Note 1 LE OE 64 Maximum Diameter Alarm See o o Remote Stop Maximum Diameter Alarm Not Used Remote Hater Resume 4 9L SL vL EL OI ve FE GE Not Used Notes 1 See Alarm Output Connection Diagrams on page 6 2 Remote contact closures are momentary only 3 Shield all signal wiring and keep away from wires carying heavy loads
15. H E 11 QUICK REFERENCE SETUP AND CALIBRATION WORKSHEET 13 15 Bad ea 16 OvervieW aa EA EA EA EO GE 16 Loading a JOb 17 Automatic Operation 17 Manual GE D c MR CE 17 Unwind Applieaon er 18 Winding Application ee 18 SPEGIEIGATIDN DT aaan 19 PARIS LIS Te a i a EIS ee dd 19 SERVICE INSTRUCTIONS Bee ee NEE ERA EIER EEE 19 WARRANTY Ee EE EE a RR EL 20 3 FORM NO L 20348 F 0705 INTRODUCTION The Nexen TCD 600 is a non contact open loop tension control system that provides reliable web tension control that s easy to use and requires minimum attention by the operator The TCD 600 maintains constanttension by varyingthe brake or clutch torque with the change in roll diameter When the set point is adjusted for the maximum torque needed at full roll diameter the TCD 600 applies a correction based on its diameter calculation and proportionately increases clutch torque as a wind roll builds up or decreases brake torque as an unwind roll becomes smaller For example Figure 1 showsasystem thatincludes a sensor which measures the diameter of the roll The sensor sends this information to the TCD 600 Controller An operator enters into the TCD 600 the maximum and minimum s
16. Max Alarm NC Accept Changes Yes or No Y N Unwind Applications Sonic Sensor Edit Job Parameters Full Roll 060 00 in Setpoint 010 0 Hold Torque 010 0 Stop Mult 01 0X Stop Time 003 0 sec Start Time 003 0 sec Diam Hyst 0 10 in Min Dia Alrm 006 00 Min Alarm NC NO Max Dia Alrm 050 00 Max Alarm LNC NO Accept Changes Yes or No Y N Unwind Applications Prox Sensor Edit Job Parameters Full Roll 060 00 in Setpoint 010 0 Hold Torque 010 0 Stop Mult 01 0X Stp Time 003 0 sec Strt Time 003 0 sec IDiam 60 0 in Thick 0 005 in Min Dia Alrm 006 00 Min Alarm NC NO Max Dia Alrm 050 00 Max Alarm NC NO Accept Changes Yes or No Note Refer to Glossary of Terms for explanations of the parameters FORM NO L 20348 F 0705 Y IN 18 OUICK REFERENCE SETUP AND CALIBRATION WORKSHEET Unwind Applications Prox Encod Sensor Edit Job Parameters Full Roll 060 00 in Setpoint 010 0 96 Hold Torque 010 0 Stop Mult 01 0X Stp Time 003 0 sec Strt Time 003 0 sec Diam Hyst 0 10 in Min Dia Alrm 006 00 Min Alrm NC NO Max Dia Alrm 050 00 Max Alrm NC NO Accept Changes Yes or No Y N CAL MODE
17. OD P2 Adjustment O Adjustment Green Red Indicator FIGURE 6 Ultrasonic Sensor PROXIMITY SWITCH FIGURE 7 MEASURING WHEEL OPTICAL ENCODER NIP ROLLER Ge e NM M Coo S PROXIMITY SWITCH FIGURE 8 ELECTRICAL CONNECTIONS 4 WARNING Before connecting any wires be sure that AC power is turned off locked and proper signage applied according to safety regulations All wiring must be shielded or run through conduit Wire runs are to be no more than 300 feet Connect all wires to the terminal strip on the back panel of the TCD 600 See Figure 9 Avoid splicing wires CAUTION Observe polarity when connecting any devices marked and CAUTION Make sure the AC Select Switch is in the proper position or damage could result to the TCD 600 See Figure 9 Refer to Figure 10A and 10B for all electrical connec tions All wires to be inserted into the modular connectors must be prepared ahead of time by stripping the insulation 1 4 from the end of the wire See Figure 9 Twist the end of each wire to be sure there are no loose or frayed strands Unplugging the modular connectors will make wiring easier CAUTION Wires must be stripped to the proper length to avoid electrical shorting After making all the connections double check each one for accuracy and clamping tightness Apply AC power STRIP INSULATION 1 4 BACK
18. S RIGHT SHIFT BUTTON MINUS LEFT ENTER BUTTON OUTPUT STATUS INDICATOR ne en AUTO STOP ON 010 0 DIAM 12 01IN 2 4 FIGURE 36 ne gt lt en GREE REN ERES TCD 600 AUTO RUN ON 010 0 DIAM 12 01IN kA OUTPUT a go FIGURE 37 ne gt lt en GREE REN ERES TCD 600 MANUAL RUN ON 010 0 DIAM 12 01IN ER OUTPUT a go FIGURE 38 MANUAL OPERATION NOTE In Manual Mode the output will not change automatically with roll diameter the operator MUST make all corrections as the roll size changes To manually operate the machine press the Upper Select button to return the top line of the display to the Run Mode See Figure 37 Use the plus or minus button to select Manual then press Enter The display will indicate the set point of the currently selected job and the current roll diameter See Figure 38 After making sure that the Output is On press the Start button While the machine is running you can vary the output up or down by pressing the plus and minus buttons continued 21 FORM NO L 20348 F 0705 OPERATION continued UNWIND APPLICATION With a full roll on the unwind shaft the Start contact or button is momentarily closed or pressed to put the TCD600 into Start operation at the same time the machine begins pulling the web During the Start operation which lasts for the duration of the Start Time see figure 39 TCD600 s output is at the Hold Torque
19. Then press Enter 2 Thelower display line will advance to Language See Figure 13 Press the plus or minus button to select the desired language then press Enter 3 Thelower display line will advance prompting you to select millimeters or inches See Fig 14 Press the plus or minus button to select the desired measurement then press Enter 4 Thelower display line will advance prompting you to select wind or unwind See Figure 15 Wind controls tension during the increase in the diameter of a roll and Unwind controls tension during the decrease in the diameter of a roll Press the plus or minus button to select WIND or UNWIND then press Enter 5 Thelower display line will advance prompting you to select the type of sensor to be used The selections are Sonic which stands for Ultrasonic Sensor Prox which stands for proximity sensor or Prox Encod which stands for Proximity Sensor Optical Encoder See Figure 16 Press the plus or minus button to select the proper type of sensor then press Enter NOTE When the Prox Encod combination is selected the lower display will advance revealing the following Counts 00833 100 in 2540mm If you are using a Nexen Optical Encoder this information is the Factory default setting and you can proceed to the next step by pushing Enter If you are using another Optical Encoder you will have to calculate the number of pulses per 100 in 2540mm of web length and replace the default
20. e display See Figure 30 Using the plus or minus button enter the maxi mum roll diameter then press the Enter button Computing will appear in the display for a few seconds See Figure 29 then the display will return to the CAL MODE See Figure 26 Advance to Step 11 to enable lockout FIGURE 24 FIGURE 25 t e OUTPUT D FIGURE 26 n D FIGURE 27 EE t i OUTPUT FIGURE 28 Ed OUTPUT FIGURE 29 continued 15 ne en CREE Ran GRRE TCD 600 SET JOB OFF Edit Load Save e go ne en LOAD JOB OFF Default Job a EE ne en CREE SEN ETE TCD 600 CAL MODE OFF Edit or Default a a go ne gt lt en CREE REN ERA TCD 600 CAL MODE OFF Diam aD ne gt lt en CRE ROH STG TCD 600 CAL DIAMETER OFF Core Diam 001 00 in e go ne gt lt en CREE REN ERA ToD 600 CAL DIAMETER OFF Computing e go FORM NO L 20348 F 0705 SETUP PROCEDURE continued CALIBRATION MODE continued NOTE The following procedure is for either the Proximity Switch system or the Proximity Switch Encoder system 7 CAL DIAMETER Core Diam will appear in the display See Figure 28 Using the plus or minus button enter the desired core diameter then press the Enter button CAL DIAMETER Max Diam will appear in the display See Figure 30 Using the plus or minus button enter the desired maximum diameter then press the Enter but
21. ectrical noise problems A 15 VDC power supply is required and connects to terminal block positions 1 and 2 see figure 10A The TCD600 is shipped in the non isolated setting Two internal jumpers JP1 and JP2 must be set before the control outputs can be isolated Refer to the following procedure to change the setting Note Only the tension control outputs can be isolated The diameter output signal can not be isolated from within the TCD600 Changing the Output Isolation Setting 1 Disconnect all electrical power from the TCD600 2 Remove all terminal block plug connectors from the back of the TCD600 3 Remove six fasteners from the back nomenclature panel 4 Remove the upper left hand fastener from the front membrane switch panel See figure 10C 5 Pull the top panel of the enclosure toward the back until it is completely removed FIGURE 10C 6 Locate JP1 and JP2 on the printed circuit board 7 Set the jumpers for the desired setting See figure 10D JP2 8 Replace the top cover back nomenclature panel and Non Isolated Isolated all fasteners Outputs Outputs 9 Plug the connectors back into the terminal blocks 10 Connectthe 15 VDC power supply to terminal block terminals 1 and 2 Terminal 1 15 VDC Terminal 2 DC common E ur li Wi O00000000000000000000000 11 Reconnect electrical power to the TCD600 E hi
22. exen installation or maintenance manual for the Product 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 no tice 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 PER SON FOR INCIDENTAL DAMAGES SPECIAL DAMAGES CONSEQUENTIAL DAMAGES OR OTHER DAM AGES 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
23. its customers or other third parties In no event shall Nexen be li able 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 bar gained 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 whatso ever 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 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 24 FORM NO L 20348 F 0705
24. ize of the roll along with other information that applies to the specific job The TCD 600 using this information varies the amount of torque applied to a brake or a clutch as the roll diameter changes As a result a constant tension is maintained on the web This example is only one of the many potential control systems that can be built around the TCD 600 The TCD 600 will work with three different sensor configu rations Ultrasonic Sensor Proximity Switch and Proximity Switch Optical Encoder combination The Ultrasonic Sensor configuration measures roll diameter directly See Figure 2 The Proximity Sensor configuration counts the number of roll revolutions This value plus the web thickness enables the TCD 600 to estimate the roll diameter See Figure 3 The Proximity Switch Optical Encoder combination accurately calculates the roll diameter by measuring the amount of web paid out for each revolution of the roll The TCD 600 provides three output signals two for control 4 20 mA and 0 10 VDC and one for monitoring 0 5 VDC The 4 20 mA output signal is typically used with Nexen Electro Pneumatic Converters to vary the air pressure applied to air actuated tension brakes and clutches The 0 10 VDC output signal is often used as a speed or torque reference voltage for motor drive controllers or is used with power supplies for electric brakes or clutches The 0 5 VDC output signal provides a way to remotely monitor roll diameter
25. lect Set Job then press Enter The upper display line changes to Set Job and the lower display line allows you to select Edit Load or Save See Figure 17 Select Edit and press Enter The upper line advances to Edit Job The lower line displaying Full Roll will scroll though a list of parameters that can be set for the specific job See Figure 18 For example to change the value of the Full Roll parameter press the plus or minus buttons to set the size of the full roll diameter Then press Enter and the next parameter will appear on the lower line which will be Setpoint Use the Quick Reference Worksheets on Pages 13 15 to enter the settings for the rest of the parameters For expla nations of the parameters see the Glossary of Terms After stepping through and setting all of the parameters you are then prompted to accept the changes you have made See Figure 19 If you are not ready to accept them or want to reset the parameters to default values select N for no and press Enter You will be returned to the beginning of the Set Job Mode If you are ready to accept the changes you have made select Y for yes and press Enter The display will return to the Set Job Mode The TCD 600 can store up to 5 different jobs into memory Press the plus or minus button to select Save then press Enter See Figure 20 Using the plus or minus button select the number for the job that is to be saved Choose from Job 1 through Job 5 then
26. n to squeeze the Control Panel between the Slide Bars and the TCD 600 Bezel BT In 135 mm Wall Mount Configuration 2038 Screws Provided 4 0 In zi l 7 3 In 102 mm 186 mm FIGURE 5 continued 5 FORM NO L 20348 F 0705 INSTALLATION continued SENSOR MOUNTING An Ultrasonic Sensor can measure the change in roll radius by bouncing soundwaves off the material enabling the TCD 600 to calculate roll diameter For calibrations to be accurate the sensor must be installed perpendicular to the axis of the wind or unwind shaft Also the Ultrasonic Sensor must be mounted at least four inches 100mm away from the maximum diameter roll ADJUSTMENT OF THE ULTRASONIC SENSOR Nexen s Ultrasonic Sensor is factory adjusted for a 4 to 40 inch range and typically does not require re adjustment prior to use Ifa shorter range is desired then re adjustment may be performed by connecting a voltmeter to the sensor s output and turning P1 for the near point adjustment and P2 for the far point adjustment See figure 6 Adjust P1 and P2 until the output voltage covers as much of the O to 10 VDC range as possible over the desired distance NOTE The indicator on the end of an Ultrasonic Sensor shows an indication of signal strength The indicator will light GREEN when a target is out of range and fades to RED as a target moves into range depend ing on how much reflected signal it receive
27. nexen WEB CONTROL PRODUCTS User Manual gt gt gt Open Loop Tension Controller TCD 600 FORM NO L 20348 F 0705 In 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 1999 Nexen Group Inc FORM NO L 20348 F 0705 2 Table of Contents NS EP SN Oe ee er EEE 1 INSTALLATION EG D LR ED 2 PANEL DIMENSIONS AND MOUNTING INSTRUCTIONS 2 ELECTRICAL CONNEC TIONS vrees ese ees bee ee EE EE Be He RE ee AE Ee An rue 4 GLOSSARY OF TERME iseer E 7 SETUP PROCEDURE oie soseer seun Ee ke EA RA EE ee ee ASe nannan 8 Machine EE EE EE i Ee N N N ee ee ee eN 9 lol cm AE AA a a OE ER ME 9 a Bra O
28. or AC supply power FIGURE 10A continued FORM NO L 20348 F 0705 8 ELECTRICAL CONNECTIONS continued FIGURE 10B TCD 600 ALARM OUTPUT CONNECTION DIAGRAMS gt User Supplied VDC See Specifications for maximum voltage TCD 600 R See Note To PLC Input T VDC Common L__ User Supplied NOTE The minimum value of resistor R is 10 x VDC Alarm Output Tied to PLC Input gt User Supplied External Indicator See Note R VDC See Specifications for maximum voltage voc Common L user Supplied NOTE The minimum value of Resistor R is equal to VDC divided by the maximum current limit of the Indicator Alarm Output Tied to External Indicator gt User Supplied See Notes External Coil 29 31 VDC See Specifications for 1N4002 maximum voltage voc Common Ly User Supplied NOTES 1 Be sure the current requirement of the External Coil does not exceed the capability of the alarm output TCD 600 2 Any inductive load such as a relay coil must have a 1N4002 or equivalent diode across it as shown Alarm Output Tied to External Inductive Coil FORM NO L 20348 F 0705 TCD600 ISOLATED OUTPUTS The 0 10 VDC and 4 20 mA tension control outputs can be isolated from the TCD600 s power supply This is often done when connecting the outputs to a motor drive system or whenever there is a concern about ground loops caus ing el
29. rt button or momentarily close the Start Contact input The TCD600 will now automatically turn on the output and run the last job that was loaded The display will indicate the output level and roll diameter See Figure 37 In some situations it is necessary to maintain a steady unchanging output By holding down the Hold Resume button the output of the TCD 600 will remain constant When the Hold Resume but ton is released the TCD 600 readjusts the output according to the current roll diameter Pressing the Stop button brings the current job to a stop Press the Hold Resume button to resume control at the diameter and output levels when the Stop was initiated as when stopping and restarting in mid roll Press the Start button to begin control of a new roll at hold level and start diameter NOTE The Start Resume and Stop functions can be controlled remotely using momentary contact closures See Figure 10a Using maintained contact closures will prevent the front panel buttons from functioning During Automatic mode the output set point can be adjusted while the process is running See Figure 37 Use the plus and minus buttons to change the output set point either up or down NOTE The controlled output is represented as a percentage 100 is full output i e 10 VDC or 20 mA SHIFT BUTTON 2 LINE DISPLAY NEXEN LOGO BUTTON STOP BUTTON RUN STOP OFF HOLD RESUME BUTTON SELECT AUTO MANUA almi 5E PLU
30. s from a target A Proximity Switch See Figure 7 is designed to count revolutions as the roll turns by sensing an iron or steel target once every revolution Mount the Proximity Switch to a secure nonrotating member and set the gap between the Nexen Proximity Switch and the target to 20 to 40 inch 5 1 10 3mm The target must be large enough to trigger the switch and can be mounted to the roll shaft or any other mechanical component that rotates at the same speed as the roll When using an Optical Encoder along with a Proximity Switch See Figure 8 precise diameter measurement of the roll can be achieved The Optical Encoder is coupled to a measuring wheel which when rotated one full turn equals 12 inches The Optical Encodertranslates this rotation into 100 pulses per foot As a result the Optical Encoder must be mounted so as to ensure that the measuring wheel rotates at the same speed as the web moving through the machine A good mounting location would have the measuring wheel making contact with one of a pair of nip rollers because the pressure between these rollers ensures that there will be no slippage between the web surface and the roll surface However the wheel should NOT make direct contact with the web as that might scratch or mar the surface of the web FORM NO L 20348 F 0705 4 100mm Minimum 40 1 000mm Maximum ADJUSTING SCREWS Near Point Far Point P1
31. s involving many different materials the only way to find the right amount of Taper is through experimentation Toolittle Taper will yield telescoped rolls and too much Taper will yield soft rolls continued FORM NO L 20348 F 0705 20 OPERATION continued SELECT UPPER BUTTON SELECT LOWER NOTE A Job must be Loaded before BUTTON operating the TCD 600 Once a Job is Loaded into memory the TCD 600 will recall this Job on power up OUTPUT BUTTON FIGURE 35 LOADING A JOB Pressthe Upper Select Button until Set Job is displayed Next press the plus or minus button to select Load then press Enter Display will advance to Load Job Now press the plus or minus button to select from Job 1 Job 5 After selecting a job press Enter The display will briefly show Job Loaded then go back to Set Job AUTOMATIC OPERATION Press the Select Upper button to advance the top line of the display to Run Mode See Figure 35 Use the plus or minus button to select Auto and press Enter The display will indicate the currently selected job s hold torque and the current roll diameter See Fig ure 36 Make sure that the Output is turned On by pressing the Output button and observing the Output Status Indicator Press the Start button The TCD 600 will now automatically run the job using the preset parameters to calculate the roll diameter The display will indicate the output level and roll diameter or After power up press the Sta
32. tension it is necessary to vary the CONSTANT output level with the change in roll diameter The TCD 600 applies a correction based upon a diameter calculation and proportionately increases the output level as a wound roll builds up or decreases the output level as an unwind roll becomes smaller zO wzm The Setpoint setting will be different for each type and each 0 CORE EE OD width of material run on a specific machine Therefore Set point mustbe determined by experimentation As experience FIGURE 34 is gained on a particular machine determining the Setpoint for a given job will become easier Output level as illustrated in Figure 33 is decreased all the way to theoretical zero diameter Of course the roll only decreases to core diameter thus there is a positive output level applied at the core diameter allowing constant tension control from maximum roll diameter down to the core Some winding operations require taper tension a relatively higher web tension applied at the core which gradually de creases as the wound roll builds in size See Figure 34 In orderto have tapertension the torque of the winding clutch or motor must still increase with roll diameter but notas much as would be required to maintain constant tension Taper tension is achieved by adjusting the Taper setting in the Job Edit mode The Taper range can be adjusted from O to 86 5 of the tension Setpoint Due to the vast variety of application
33. ton NOTE Minimum Output is used only for Wind applications that use air actuated clutches This feature enables you to adjust the minimum TCD 600 output needed to overcome the mechanical characteristics of the clutch e g a release spring If not used advance to step 11 to enable lockout 9 10 11 CAL MODE Diam Min Out will appear in the display See Figure 31 Using the plus or minus button select Min Out then press the Enter button CAL MIN OUT Min Output will appear in the display See Figure 32 Using the plus or minus button adjust the output until the clutch is fully engaged then decrease the value until the clutch is slightly disengaged and press the Enter button After calibration is completed simultaneously press and hold the Nexen and Stop buttons for 3 seconds to enable the lockout feature and prevent any unintended changes to the calibration settings FORM NO L 20348 F 0705 16 OUTPUT FIGURE 30 t LA i OUTPUT FIGURE 31 t 23 OUTPUT FIGURE 32 nexen CAL DIAMETER OFF Max Diam 060 00 in e go ne en CAL MODE OFF Diam Min Out e go ne en CAL MIN OUT OFF Min Output 000 0 e r3 OUICK REFERENCE SETUP AND CALIBRATION WORKSHEET SETUP MODE Set Machine DEFAULT Language English English Millimeters Inches Inches Wind Unwind Wind Sonic Prox Prox Encod Sonic Counts For Prox and
34. up the operator has access to the Standby Mode Run Mode and the Setup Mode To gain full access for setting up and calibrating press the Nexen Logo button while simultaneously pressing the Stop button and hold them until SETUP ENABLE appears on the display Full access allows changes to be made to the Machine parameters and sensor calibration This access is allowed until the unit is powered down or until the same key sequence is repeated Pressing the Select Upper button causes the top line of the display to step through the operation modes Run Mode Setup Mode Calibration Mode and back to Standby Mode Pressing the Select Lower button while in the Standby Mode will enable you to quickly view the parameter settings of the current loaded job These settings cannot be changed while in the Standby Mode Pressing the Select Lower button while in Automatic Run Mode will enable you to view and change the following job parameters Setpoint Taper 96 and Diam Hyst Diameter Hysteresis Pressing the Minus and Plus buttons enables you to select values while in Run Mode Setup Mode and Calibration Mode Selected values are displayed inside brackets The Enter button is used to enter values or customized settings into the TCD 600 s memory Pressing the Output button toggles on and off the output signal being sent from the TCD 600 to a Motor Controller or a pneumatic device for clutches and brakes During the Setup and Calibration Modes
35. y Sensor only systems The TCD 600 uses the Initial diameter and the Thickness to estimate the roll s diameter by subtracting or adding one thickness amount for every revolution of the roll Thick can be adjusted from O to 1 0 inches 0 to 25 4 mm Minimum Diameter Alarm This is used for Unwind applications where an alarm output is triggered when the roll size has decreased to a specified diameter adjustment range is O to 650 inches 0 6500mm Minimum Alarm Configuration Minimum Diameter Alarm output can be configured for Normally Closed NC or Normally Open NO operation Minimum Output is used only for Wind applications that use a clutch This feature sets a minimum output level to overcome the mechanical force of the clutch for engaging Maximum Diameter Alarm This is used for Wind applications where an alarm output is triggered when the roll size has increased to a specified diameter its adjustment range is O to 650 inches 0 6500mm Maximum Alarm Configuration Maximum Diameter Alarm output can be configured for Normally Closed NC or Normally Open NO operation After entering in new information the TCD 600 will ask if the changes should be accepted select Yes Y or No N 11 FORM NO L 20348 F 0705 SETUP PROCEDURE The front panel of the TCD 600 has nine function buttons and a two line display See Figure 1 1 The TCD 600 has afeature that locks out access to certain setup and calibration functions Upon powering
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