Tension Controller
Contents
1. 18 TUNING 18 Setpoint 19 POV 1 19 gt 19 Network Port Setup 20 Operation 20 Manual Control 20 Unwind Appleation er 21 Splicing Unwind Application ee 21 Wind Application u GUTE ED 22 Splicing Wind Application 22 Spring Disengaged Clutch 23 Mid Process Application 23 2 23 Specifications ee 24 Number 24 Troubleshooting 25 Service NStrUCtONS 7 26 26 Warranty a nn nn 27 3 FORM NO L 21204 C 0705 INTRODUCTION Nexen RSTC Tension2. Delay Roll Diameter Figure 23 Taper Tension with Delay NETWORK PORT SETUP MODBUS PORT SETUP R Select the Network Communications Setup icon from the toolbar Use this window to select parameters needed to establish Modbus RTU communications with a master device Baud Rate Use the pull down selection box to specify the communication speed required by the Modbus master device If connecting to Nexen s RSTC Operator Panel select 19200 Parity Use the pull down selection box to specify the type of parity required by the Modbus master device If connecting to Nexen s Operator Panel select None Stop Bits Use the pull down selection box to specify the number of stop bits required by the Modbus master device If connecting to Nexen s RSTC Operator Panel select 2 RSTC Device Address Specify the device address required by the Modbus master device If connecting to Nexen s RSTC Operator Panel select 24 Port Settings select to update the settings immediately or the next time the RSTC is powered on PROFIBUS PORT SETUP R Select the Network Communications Setup icon from the toolbar Use this window to select parameters needed to establish Profibus communications with a master device RSTC Device Address Specifies the device address required by the Profibus master OPERATION MANUAL CONTROL Manual control of the RSTC s control output is useful for troubleshooting The AUTOMATIC MA
3. WEB CONTROL PRODUCTS User Manual gt gt gt Tension Controller RSTC1000 amp RSTC1100 FORM NO L 21204 C 0908 ZN 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 Manufacturers Declaration In accordance with the CE machine directive 98 37 EC Appendix II We hereby declare that the pneumatic mechanical components described in this manual as well as their indi vidual components are intended in the configuration in which they have been supplied to be integrated into a machine They must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the Directive mentioned above or its amendments All Nexen products are designed in accordance with the manufacturing directives for pneumatic systems ac cording to EN 983 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 Techni
4. signal and sensor cable shields directly to earth ground without passing through the electronic device This will help prevent high voltage interference from coupling into other circuits within the device 5 FORM NO L 21204 C 0705 INSTALLATION Mount the RSTC within a user supplied enclosure typically the machine s controls cabinet The RSTC can be mounted CAUTION on 35 mm DIN rail or panel mounted Refer to Figure 3 Mount the RSTC in a shock and vibration free area with an ambient temperature of less than 140 F 60 C and more than 32 F 0 C FORM NO L 21204 C 0908 6 ELECTRICAL CONNECTIONS Power Indicator Reset Network Port and ee 24 VDC Common Earth Ground Alarm 1 Out Alarm 2 Out Alarm Common t Alarm Shield 0 10 VDC Output Common Control a Output A Output Common 1 Signal Shield 0 10 VDC Output Common Control en Output B Output Common t Signal Shield Control Signal Shield amp Earth Ground Control Signal Common Splice B Input Splice A Input Control Inputs Run Stop Input Signal Shield t Common Remote Tension Setpoint Input 12 VDC Excitation Common Diameter Sensor Input 24 VDC Excitation Load Cell Shield t Excitation Common 6 VDC Excitation Sensor Signal Sensor Signal Excitation Common 6 VDC Excitation Sensor Signal Sensor Signal Power cable must be less than 10 m 390 in There two terminals that require a lo
5. Controllers are used to control web tension relying on load cell based tension sensors to measure web tension As a part of a tension control system the measures the web s tension and corrects tension errors by sending a signal to change the torque output of brakes clutches and motor drive systems The RSTC automatically adapts to changes in inertia and torque as roll diameters change This ensures constant stable tension at all times and allows for faster accelerations and decelerations for a more productive web machine The RSTC does not require a diameter sensor for constant tension applications and can adapt to spliced rolls of different diameters automatically without readjustment Applications for the RSTC include unwinding mid process constant tension winding and taper tension winding RSTC1000 SYSTEM The RSTC1000 Tension Control System includes three components the RSTC1000 RSTC Operator Panel ROP and RSTC Communications Software TheRSTC1000 tension controller can be used as a slave on aModbus RTU network Because of this capability many Human Machine Interfaces and Programmable Logic Controllers PLCs can communicate directly with it Web machines that already have a capatible HMI control panel do not require the The Communications Software features setup tuning and diagnostics functions and is available from the Nexen website www nexengroup com RSTC1100 SYSTEM The RSTC1100 Tension Control System includ
6. constant level as specified by Standby Output Small Roll gt Large Roll Adaptation Web Speed Acceleration Deceleration i i Splice FORM NO L 21204 C 0908 Acceleration Initial Adaptation amp Splicing Adaptati Deceleration Run Stop Signal Signal NN SPRING DISENGAGED CLUTCH is common to use a spring disengaged clutch on a winder and this spring can affect performance if the RSTC s output becomes too low and the clutch begins to disengage Use the MINIMUM OUTPUT setting to keep the control output high enough to overcome the spring force in a spring disengaged clutch DIAGNOSTICS Select DIAGNOSTICS icon from the toolbar then press START to begin receiving data from the RSTC Communication The Diagnostics window displays real time operating information from the RSTC This can be used throughout the setup procedure to verify results from sensors and setup parameter settings All functions of the Diagnostics window are explained in the HELP files of the RSTC Communications software MID PROCESS APPLICATION Nexen s RSTC is capable of mid process tension control by adjusting the torque output of a motor or brake Mid process applications are similar to an unwind process when controlling from the upstream end of a tension zone and a rewind process when controlling from the downstream end of a tension zone Refer to Figure 13 The most notable difference is that mid pr
7. determined by TENSION SETPOINT Next as the roll decreases in size so will the Adaptation and Output values It is normal for the RSTC s output value to fluctuate slightly as long as the web tension does not During a machine stop Adaptation and Output values will initially increase to overcome a roll s inertia After a Stop signal is given when the web has come to a stop the Adaptation value will reset to INITIAL ADAPTATION When the RSTC is in Stop mode the Adaptation value will remain constant and the Output value will change depending on the web tension The MAXIMUM OUTPUT value is used to limit how high the output can rise Likewise MINIMUM OUTPUT value is used to limit how low the output can drop This is useful for applications where a minimal amount of output is necessary to over come the spring force in a spring disengaged brake NOTE If the new roll is smaller than the one used to set up Splice Adaptation the adaptation level could start out too high after a splice and the tension may become unstable until the gains have adapted down At the time of the splice the RSTC must receive a Splice A or Splice B signal This will cause the corresponding control output to become the active output controlling web tension If the new roll is to be controlled by Output B then the splice signal is given to the Splice B input After the splice signal is received the opposite control output goes into standby mode causing the out
8. excessively stop the machine Decrease Gain by 0 5 and return to step 3 e f performance is satisfactory proceed to step 4 4 Load a small roll on to the roll stand 5 Start the machine and note if there are excessive output oscillations e If the output oscillations are excessive stop the machine Reduce the Gain by 0 5 and return to step 5 6 Continue to test for output oscillations until the roll is as small as practical During tuning if the Gain value reaches 1 0 and further adjustment is required then stop the machine decrease Stabilization by 1 0 set Gain to 2 5 and return to the tuning process Likewise during tuning if the Gain values reaches 10 0 and further adjustment is required then stop the machine increase Stabilization by 1 0 set Gain to 2 5 and return to the tuning process FORM NO L 21204 C 0705 SETPOINT Tension Setpoint Enter the desired web tension level The Tension Setpoint range is set by the Maximum and Minimum Tension Setpoint values in the Setup window ADVANCED Initial Adaptation is the beginning point for the adaptation process after the RSTC enters Run mode Tension oscillations could occur during a machine start when roll size is near core diameter if this value is set too high Tension could be slow to come up to setpoint after a machine start if this value is set too low Best recommendation is to use the default value and only change if absolutely necessary Splice A
9. frequency MHz range electrical noise both ends of the shield need to be tied to earth ground e Keep cable length and unshielded leads as short as possible Think of them as antennae for noise e Use power line filters to suppress interference on Snubber the AC voltage lines that power the unit I I I I I L e Place a resistor capacitor network snubber across inductive coils such as relays and solenoids in order to stop electrical interference at the source See Figure 2 e Isolate signal and sensor cables from cables carrying AC voltages power for high current loads or relays and solenoids Either relocate the signal and sensor cables away from other cables or use grounded metal conduits to shield them This will reduce the potential for noise interference between the signal and sensor cables and the other noisy cables Figure 2 Snubber applied across relay coil For environments that experience high levels of static electricity follow these additional guidelines e Remove the static charge from material carrying it In the case of webs that carry static charges there are static charge removal products available such as static bars and ionized blowers e Ensure that sensors and machine frames grounded to earth through a low impedance path e Wrap grounding tinsel around sensors and cables that are close to the source of the static electricity and ground the tinsel to earth e
10. low the RSTC assumes the machine is stopped When the Run Stop input signal transitions to a maintained high the RSTC algorithm will begin adapting to account for the roll s diameter and inertia The web must be in motion for unwinding applications or in tension for winding applications when this signal goes high otherwise the Adaptive Gain will increase to maximum After the Run Stop signal transitions back to low the Adaptive Gain will return to Initial Adaptation Gee OPERATION section CONTINUED FORM NO L 21204 C 0908 16 Figure 19 Run Stop Signal Selection Screen Run S anaL MOMENTARY When the Start Stop input signal pulses high the RSTC algorithm will begin adapting to account for the roll s diam eter and inertia The web must be in motion for unwinding applications or in tension for winding applications when this signal goes high otherwise the Adaptive Gain will increase to maximum After the machine stops the RSTC will continue trying to adapt until the Run Stop input pulses high again and forces the adaptation process to start over from Initial Adaptation Run Stop SigNAL MOMENTARY When the Run Stop input signal pulses high the RSTC algorithm will begin adapting to account for the roll s diameter and inertia The web must be in motion for unwinding applications or in tension for winding applica tions when this signal goes high otherwise the Adaptive Gain will increase to maximum After the Run Stop
11. 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 shall 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 Nexen Group Inc 800 843 7445 560 Oak Grove Parkway Fax 651 286 1099 Vadnais Heights MN 55127 www nexengroup com ISO 9001 Certified 97 FORM NO L 21204 C 0705
12. 0 0 5350 13 000 5 5800 30 000 155 9200 FORM NO L 21204 C 0908 26 To determine WK of a normal shaft or disc multiply the WK from the chart by the length of the shaft or thickness of the disc in inches Note For hollow shafts subtract WK of the i d from Wk of the o d and multiply by the length 2 For solid cylinders of a given weight WK is estimated by WK W Where WK intertia in Ib ft cylinder radius in feet W weight in pounds 3 For solid or hollow cylinders the inertia is calculated by the following equations Solid Cylinder Hollow Cylinder WK 000681 pLD WK 000681 p L D D D N lt Where WK lb ft D D D and L are in inches Ib in where aluminum 0924 p cast iron 260 steel 282 Calculate the inertia of complex concentric rotating parts by breaking the part into simple cylinders calculating the inertia or each and summing the values 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 i
13. NUAL button of the OPERATION MODES pane in the DIAGNOSTICS window indicates the current control mode see Figure 29 Pressing AUTOMATIC will switch control to MANUAL mode and change the button display to MANUAL indicating the new control mode A window will appear allowing you to manually adjust output levels See Figure 26 The INCREASE and DECREASE buttons increase or decrease the control output level to the brake clutch or drive in 1 or 10 increments Press SWITCH TO AUTOMATIC CONTROL to return to automatic control mode FORM NO L 21204 C 0908 20 x Port Setup Baud Rate HEN Parity None Stop Bits z Device Address RSTC Device Address 24 Port Settings Update immediately Update on next power up Communication Retrieve Cancel Figure 24 MODBUS Port Setup Screen Profibus Port Setup x Device Address RSTC Device Address 56 Communication Retieve Cancel Figure 25 PROFIBUS Port Setup Screen Manual Control 10 Increase AN 1 Increase 1 Decrease y 10 Decrease Figure 26 Manual Control Window UNWIND APPLICATION A typical unwind application begins with a new full roll To insure that the web tension reaches setpoint as quickly as possible the Splice signal can be used to reset Adaptation to a higher level set by SPLICE ADAPTATION before the machine starts This shortens the time it takes for the RSTC1000 to adapt its gains to the new ro
14. TC1000 RSTC1100 Modbus RTU Network Profibus DPV1 Network FORM NO L 21204 C 0908 964523 964528 24 TROUBLESHOOTING Probable Cause Diagnosis Test Corrective Action Power Indicator is not illuminated Control inputs do not respond RSTC will not go into Auto mode Tension fluctuates in automatic mode Output goes to 0 during unwinding roll acceleration Output goes to 0 and tension rises above setpoint when roll unwinds at constant web speed Output goes to 100 during deceleration and tension falls below setpoint Output goes to 100 and tension falls below setpoint when roll winds at constant web speed Improper or missing signal Run signal not provided to control input or software command not given Run Stop signal not set up properly RSTC in manual mode Improper settings or calibration Web machine problem Machine acceleration rate too high Acceleration of the unwinding roll shaft causing tension increase Machine deceleration rate is too high and there is not enough torque Not enough torque for the size of roll and the tension setpoint Check for 24 VDC across terminals 1 and 2 using a voltmeter Measure the voltage at inputs 41 43 and 44 Start machine and watch for Run Stop to go high on Diagnostics window Check Run Stop configuration in Signal Calibration window Check Automatic Manual button on Diagnostics window Tension not fluctuating i
15. al outputs Common is the return line for the control signal outputs Signal Shield is the terminal for connecting the cable shield to chassis ground Load Cell Inputs The RSTC will accommodate two web tension sensing load cells Polarity of the load cell signals does not matter as long as the polarity of both load cell input signals are oriented the same The Sensor Signal is for the tension level signal from the load cells The 6 VDC Excitation is the power supply for the load cells Excitation common is the return line for the load cell power Load cell cable shields must be tied directly to Earth Ground for best noise reduction Diameter Input This input provides winder roll diameter measurements for the taper tension algorithm and is not used for anything else Diameter signal can be provided by a diameter sensor or voltage source such as a PLC s analog output card capable of 0 12 VDC maximum signal range The 24 VDC Excitation and 12 VDC Excitation provide power when using a diameter sensor Common is the return line for the diameter signal and sensor excitation Diameter Sensor Shield is the terminal for connecting the diameter sensor cable shield to chassis ground Remote Tension Setpoint This 0 12 VDC input allows the tension setpoint to be set by an external potentiometer or analog signal See Figure 7 Remote Tension Setpoint is scaled such that 0 V corresponds to Minimum Tension Setpoint and 12 V corresponds to M
16. aximum Tension Setpoint When using a PLC that outputs lower than 12 V adjust the Maximum Tension Setpoint to compensate Before using Remote Tension Setpoint it must be enabled see TUNING afterwards tension setpoint changes from all other sources are ignored Web Tension Monitor Web tension can be monitored as a0 10 VDC or 4 20 mA signal from Control Output when enabled see SETUP Web Tension Monitor is INPUT OUTPUT DESCRIPTIONS CONT scaled such that 0 V or 4 mA corresponds to Minimum Tension Setpoint and 10 V or 20 corresponds to Maximum Tension Setpoint If Control Output B is being used as a web tension monitoring output then it is not available for use as a web tension control output Only Control Output A can be used for tension control in this instance INPUTS Run Stop When 12 24 VDC is applied to this digital input for at least 100 milliseconds the RSTC will respond according to Run Stop option selected during setup of the RSTC refer to SIGNAL CALIBRATION and cause the RSTC to go into the run mode or the stop mode The RSTC will actively control tension in both the run and stop modes however the RSTC will only adapt its control gains in the run mode During stop mode all control gains are held constant NOTE For unwinding applications do not provide the Run signal when the web remains stopped This will cause the RSTC to increase its gains too much and produce tension oscillatio
17. ble to decrease any further No control can also be cause by a large roll decelerated too quickly causing the output to go to 100 but the web tension remains below setpoint High Tension Web tension is greater than the high tension limit Low Tension Web tension less than low tension limit Max Output Control signal output has reached maximum output limit typically 100 Zero Output Control signal output has reached minimum output limit typically 0 The alarm outputs can be isolated from the RSTC power supply by using a separate power source and common Alarm Common is the return line for the alarm signal Alarm FORM NO L 21204 C 0908 10 Shield is the terminal for connecting the alarm cable shield to chassis ground Control Outputs The Control Output signal is used to change the torque output of a pneumatic brake or clutch via an electro pneumatic converter or a motor drive system for the purpose of controlling tension There are two channels of control outputs Control Output A and Control Output Each channel has a 0 10 VDC and 4 20 mA output signal All Control Outputs are isolated from the RSTC power supply Only one channel at a time can be used to control tension When one channel is active the other channel is in standby mode The choice of whether a Control Output is active or in standby mode is made with the Splice Control Inputs The 0 10 VDC and 4 20 mA terminals are the control sign
18. cal Support 800 843 7445 651 484 5900 www nexengroup com Nexen Group Inc 560 Oak Grove Parkway Vadnais Heights MN 55127 ISO 9001 Certified SE Copyright 2005 Nexen Group Inc Table of Contents Introduction re ER 4 Wiring Installation Guidelines 5 IRS teal aee eee eeaeee ea eneee 6 Electrical Bone ne 7 Input Output Descriptions Hm 10 Sie o Orr res re ee ee ee pr 12 RSTC to PG USB Communications 12 Display 12 Setup u HE EEE EEE ER ee 12 Torque Actuator 13 Tension ZONE 13 Alarms 14 Me 14 nn 14 Signal Calibration 15 Tension Signal Calibration 15 Diameter Signal 16 Run Stop Signal Selection 16 Tuning 18 RSTO Tuning Window
19. daptation is the beginning point for the adaptation process after the RSTC receives a Splice signal For unwinding applications this value is typically set higher than Initial Adaptation and gives the adaptation process a jump start as the splice process usually involves larger rather than smaller rolls The idea is that the adaptation TAPER TENSION During winding applications it is often necessary to re duce the tension setpoint as the roll increases in diameter in order to prevent excessive internal roll stresses from causing roll defects such as starring telescoping and crushed cores Decreasing the tension setpoint is handled automatically when a roll diameter sensor or signal is used to provide the winding roll diameter to the RSTC Taper Taper determines the amount that the tension setpoint is reduced in a linear fashion as the winding roll diameter increases Larger values will increase the rate of tension setpoint decrease while smaller values will reduce the rate of tension setpoint decrease Refer to Figures 22 and 23 The tapering of the web tension will continue until the roll is finished or Minimum Tension Setpoint is reached Taper Delay Taper Delay will prevent a decrease in ten sion setpoint from happening until the roll reaches this diameter Taper Enable Select ON to enable web tension tapering or OFF to disable this feature Use the following formula to calculate Taper for Roll Diameter gt Delay Tap
20. er Desired Tension Change Unit Beginning Tension Setpoint roll dia delay Unit 1000 for imperial units lb amp in 25400 for metric units N and mm FORM NO L 21204 C 0908 Remote SP Select ON to enable tension setpoint by external analog signal See INPUT OUTPUT DESCRIPTIONS section or OFF to disable this feature When enabled tension setpoint changes from all other sources are ignored process is started closer to its final value in order to arrive at the desired gains quicker It is important to not set Splice Adaptation so high that when a smaller than average roll is spliced the tension begins to oscillate Best recommendation is to use the default value and only change if absolutely necessary For winding applications this value is set equal to Initial Adaptation Adaptation Rate effects how fast the RSTC adapts to a roll s diameter and inertia If set too low the time taken to adapt will be long and the tension would be slow to come up to the setpoint If set too high the time taken to adapt will be short and a high frequency tension oscillation could result Best recommendation is to use the default value and only change if absolutely necessary Constant Tension Small Value Tension Setpoint Tension Large Taper Value Minimum Tension Setpoint Roll Diameter Figure 22 Taper Tension Constant Tension Torsion Setpoint i 1 1 1 1 1 1 1 Taper Tension 1
21. er are to be displayed in units of pounds and inches Select METRIC Min Core Diameter 3 if tension and diameter are to be displayed in units of Web Width in 40 newtons and millimeters Material Paper or Plastic Language Select the language from the drop down menu that the ROP will display Outputs Minimum Output 2 0 Press SEND to update the RSTC Maximum Output 100 Standby Output 0 SETUP WINDOW Tension Monitor On Off Communication Select the SETUP icon from the toolbar See Figure 11 Retrieve Cancel Note After changing values the SEND key must be pressed to send the values to the RSTC Figure 11 Setup Screen FORM NO L 21204 C 0908 12 TORQUE ACTUATOR Actuator Select from the Torque Actuator drop down menu the type of actuator the RSTC will control Actuator Inertia Enter the rotor inertia of the brake or clutch in the designated imperial or metric units The choice of units is determined by selecting the DISPLAY icon and then selecting Imperial or Metric in the UNITS pane Inertia values for Nexen Brakes and Clutches can be found in the Nexen catalog or website For drive systems enter the mo tor rotor drive pulley and shaft coupling inertias Refer to Appendix for inertia formulas and table of values Use an Actuator Inertia value of 1 0 in cases where the actual value is not known TENSION ZONE Select whether the RSTC will control a
22. es two components the RSTC1100 and RSTC Communications Software The RSTC1100 tension controller can be used as a slave on a Profibus DP network Because of this capability many Human Machine Interfaces and Programmable Logic Controllers PLCs can communicate directly with it The Communications Software features setup tuning and diagnostics functions and is available from the Nexen website www nexengroup com MOUNTING The RSTC is designed to mount inside the machine s control cabinet alongside other controllers PLCs relays etc Small size and its DIN rail mounting capability make installation fast and easy Pluggable connectors simplify wiring as they can be removed for convenient access to terminals Only requiring a commonly available 24 VDC supply the RSTC requires no hazardous voltages FORM NO L 21204 C 0908 4 WIRING INSTALLATION GUIDELINES This product is designed to minimize the effects of ElectroMagnetic Interference EMI on its operation but as with any electronic device proper installation and wiring methods are necessary to ensure proper operation By doing so the interference from external effects such as electrical line spikes electrical noise static electricity etc will be minimized The following methods outline wiring installation guidelines to protect your system e input and output signal and sensor cables must be shielded with the shields tied to earth ground at one end In case of very high
23. f a the Product has been installed used and maintained in accordance with any applicable Nexen 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 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
24. he RSTC power supply FIGURE 5 Alarm Output Connections FORM NO L 21204 C 0908 40 41 42 43 44 45 46 Run St un Stop 12 to 24 VDC Splice B Splice A NOTE To isolate the Control Input Signals use apower supply that is separate from the RSTC power supply Figure 6 Control Input Signals 24 25 26 27 28 29 30 31 32 33 34 Dual MB 24 25 26 27 28 29 30 31 32 33 34 Cable Shield B lt SW Sensor Colors Vsig Vex Vex Vsig Vex Vex enso enso SW or Half Bridge Strain Guage Load Cell Figure 8 Load Cell Connections 32 33 34 35 36 37 38 39 Potentiometer NOTE Potentiometer can be replaced with analog voltage signal by connecting analog signal 0 12V maximum to terminal 37 and signal common to terminal 38 Figure 7 Remote Tension Setpoint 24 25 26 27 28 29 30 31 32 33 34 Cable Shield Single MB 24 25 26 27 28 29 30 31 32 33 34 Cable Add Shield lt CFL Sensor Colors G Vsig Vsig Vex Vex enso CFL or Single Full Bridge Strain Gauge Load Cell FORM NO L 21204 C 0705 INPUT OUTPUT DESCRIPTIONS NOTE Refer to Figure 4 for RSTC Pinout USB Port This port is used to connect to a personal computer during setup tuning or diagnostic monitoring of the RSTC and is com
25. ll Splice signal is not used the web tension may take a little longer to reach setpoint after the RSTC goes into the Run mode As long as this does not present a problem then the Splice signal can be ignored When the Run signal goes high at the Run Stop input the RSTC will begin adapting from INITIAL ADAPTATION Adaptation is displayed graphically in the DIAGNOSTICS window however Adaptation and INITIAL ADAPTATION values will not match because INITIAL ADAPTATION is one of several variables used to calculate Adaptation NOTE The web must begin to move when the Run signal is given SPLICING UNWIND APPLICATION The RSTC utilizes Smart Splicing meaning that rolls of different sizes can be loaded or spliced into the machine without readjusting the controller The RSTC will adapt automatically to the new roll after receiving the splice signal When the splice input pulses high the controller will reset adaptation to the level defined by Splice Adaptation This shortens the time it takes for the RSTC to adapt its gains to the new roll The splice input can be used anytime a new roll is loaded on the machine with the machine running or stopped The splice input must be held high for at least 100 ms for the RSTC to detect this signal The adaptation process will begin immediately if the machine is running or will begin after the RSTC receives a Run signal As the roll begins to accelerate the web tension will settle on a level
26. m full roll diameter that will be used For mid process tension control applications enter 1 1 multiplied by the nip roller diameter Min Core Diameter Enter in the minimum core diameter that will be used For mid process tension control applications enter the diameter of the nip roller Avg Web Width Enter in the average web width maximum width minimum width 2 Material Select the web material to be used Paper or Plastic Steel or Aluminum from the drop down menu See Figure 14 OUTPUTS Minimum Output Used to specify a minimum output level typically set to 0 Minimum Output is often set to a value greater than zero in order to overcome the spring force in brakes and clutches that are spring disengaged Maximum Output Used to specify the maximum output level typically set to 100 Standby Output Used to specify the output level in standby mode not controlling tension Standby Output is often used in splicing unwind applications when it is desired to have some brake drag on the make ready roll Tension Monitor Select ON and Control Output B will output web tension monitor signal or select OFF and control Output B will output web tension control signal See Web Tension Monitor in INPUT OUTPUT DESCRIPTIONS section FORM NO L 21204 C 0908 14 Web Max Roll Diameter in 50 Min Core Diameter in 3 Web Width in 40 Material AE EAMES v Paper or Plastic Steel Fig
27. n manual mode indicates a problem with RSTC Fluctuating tension in manual mode indicates a machine problem Decrease acceleration rate and see if output increases above 0 Decrease web speed as roll diameter approaches core to see if output increases above 0 Decrease deceleration rate and see if output stays below 100 Decrease the tension setpoint increase taper and see if output stays below 100 25 Restore 24 VDC Correct any problems with voltage or wiring using the SPECIFICATIONS section to determine proper range Check Run Stop input wiring or control panel to make sure the command is sent properly Refer to Signal Calibration section of manual and select proper configuration Switch to Automatic using Automatic Manual button or issue Automatic command from control panel Re tune RSTC Recalibrate load cells Correct problem with web machine Decrease machine acceleration as roll inertia limits acceleration rate of machine Decrease web speed as roll diameter approaches core because roll and shaft inertia cause tension to increase above setpoint Decrease machine deceleration as roll inertia limits deceleration rate of machine or increase torque output of torque actuator Increase torque output of torque actuator or decrease tension setpoint or increase taper FORM NO L 21204 C 0705 SERVICE INSTRUCTIONS Nexen does not recommend customer servicing of this prod
28. ns when the web does finally move Splice A B When 12 24 VDC is applied to one of these digital inputs for at least 100 milliseconds the RSTC will respond by resetting Adaptation to a level determined by SPLICE ADAPTATION The RSTC will also make the corresponding Control Output active and the other standby The 12 24 VDC signal can be momentary or maintained however only one Splice Input can have the signal applied at a time After power up the RSTC will look at the Splice A and Splice B inputs If both are high or both are low then Control Output A is made active and Control Output B goes to standby Therefore apply the splice signal after power up to insure the proper Control Output is active Any output in standby mode will maintain a constant output level as determined by STANDBY OUTPUT variable Also if Web Tension Output is enabled then Control Output B is no longer available for web tension control and Splice B input is ignored The Control Inputs can be isolated from the RSTC power supply by using a separate power source and common Control Signal Common is the return line for the Run Stop and Splice A B input signals Control Signal Shield is the terminal for connecting the cable shield to chassis ground FORM NO L 21204 C 0705 SETUP RSTC TO PERSONAL COMPUTER USB COMMUNICATION Power Indicator In order to setup the RSTC a USB cable and the Reset RSTC Communications Software are required A Type A to mini T
29. ocess applications deal with constant diameters and inertias Similar to an unwind or wind application the output level of the RSTC s controlled outputs will increase when more tension is desired and decrease when less tension is desired I ij x Data Collection Start Stop Alarms No Alarms Rock Steady Acknowledge Control Tension 1 Ib 7 2 Tension 2 Ib 71 Total Tension Ib 14 3 Tension SP Ib 15 Taper SP Ib 15 Output 72 Status Run Stop Splice A Splice B Taper Tension Operation Modes Output Off _ Manual Advanced Adaptation 9 9 Diameter in 0 Chart Controls Clear Pause seconds 0 La Te Tr 10 30 40 50 60 Close Figure 29 Diagnostics Screen FORM NO L 21204 C 0705 SPECIFICATIONS POWER Input 24 VDC at 600 mA TEMPERATURE Operating Temperature 0 60 C 32 140 F DIGITAL SIGNALS Alarm Outputs 5 24 VDC 140 mA max current sinking Control Inputs 12 24 VDC 20 mA max ANALOG SIGNALS Diameter Sensor Input 0 12 VDC Remote Tension Setpoint Input 0 12 VDC Load Cell Inputs 2 channels 0 1 VDC Control Output 1 0 10 VDC and 4 20 mA Control Output 2 0 10 VDC and 4 20 mA SENSOR EXCITATIONS Load Cell Excitation 6 VDC Other Sensor Excitations CERTIFICATIONS 24 VDC 100 mA max amp 12 VDC 60 mA Certification CE PART NUMBERS RS
30. pliant with USB 2 0 Network Port This port is for communicating with the RSTC using a networking protocol Refer to the HMI PLC Design Guide for network specific information Network Indicators Indicators will illuminate to show status of network communications Refer to the HMI PLC Design Guide for network information Power Input RSTC requires 24 VDC to operate Refer to SPECIFICATIONS for current rating A green indicator visible through the top cover will illuminate when this voltage is present Common is the return line for the 24 VDC power supply Earth Ground is the terminal for connection to Earth Ground via a low resistance conductor Two terminals 3 and 46 must be connected to Earth Ground in order for cable shielding to work properly Reset A reset switch accessible through the top cover will reset the RSTC whenever depressed without having to cycle power on and off Alarms Transistor outputs that can be configured for normally open or normally closed operation Refer to SPECIFICATIONS for ratings Alarm 1 is activated whenever a web break is detected Alarm 2 is activated whenever one or more of the following conditions occur No Control control signal output has reached 0 or 100 during automatic operation and web tension is not at set point This is often caused by accelerating a large roll too quickly or excessive web speed near core Both cases can cause excessive tension with a control output at 0 and una
31. put to remain at a constant level as specified by STANDBY OUTPUT Large Roll _ ft cf of Small Roll Optimum Gain Reached 7 Splicing Adaptation Splice Signal Figure 27 Run Stop Signal A 21 Adaptation Initial Adaptation Deceleration Acceleration FORM NO L 21204 C 0705 WIND APPLICATION A typical winding application begins at core The INITIAL ADAPTATION value should be set high enough to allow the tension setpoint to be reached quickly after the Run signal is given Many winders are started before the machine begins to move the web This is not a problem as the winder is active even at zero web speed and the RSTC can control tension while in Run mode without the adaptation process adjusting the gains too high As the roll begins to accelerate the web tension will settle on a level determined by Tension Setpoint Next the roll will continue to increase in size along with the Adaptation and Output values It is normal for the RSTC s output value to fluctuate as long as web tension does not SPLICING WIND APPLICATION The RSTC utilizes Smart Splicing when transitioning to a new roll web This means that rolls of different sizes can be loaded or spliced into the machine without having to readjust the controller The RSTC will adapt automatically to the new roll after receiving the splice signal When the splice input pulses high the controller will reset the adaptation to
32. rtant to check for output oscillations during large and small roll machine start conditions Further initial tuning performed for a small roll may not result in adequate performance with a full roll as the RSTC could be sluggish Therefore start with Gain and Stability set at their default values and begin tuning with as large a roll as practical For winding applications us the default Stabilization and Gain value and only change the Gain as necessary in order to build a large roll then follow the tuning procedure 1 Set Stabilization to 15 0 and Gain to 2 5 2 Load as large a roll as practical on to the roll stand 18 x Tuning Gain 25 Stabilization 15 Setpoint Tension Setpoint 16 50 Remote SP On Off Advanced Initial Adaptation 1 Splice Adaptation 5 Adaptation Rate 10 Taper Tension 20 Delay in 100 Taper Enable C On Off Communication Retrieve Cancel Tuning Screen Figure 21 3 Start the machine and run at a moderate web speed and tension Note if the output oscillates excessively or if the amount of time taken to reach the tension setpoint after web speed becomes consistent is too long It is normal for the output value to fluctuate as long as the web tension does not e If the output oscillations are not excessive and the amount of time is too long stop the machine Increase Gain by 0 5 and return to step 3 e If the output signal begins to oscillate
33. signal pulses high a second time the Adaptive Gain will return to Initial Adaptation as the RSTC assumes the machine has stopped See OPERATIONS section 100 Machine Speed 0 Run The first time a machine driven encoder pulses Run Stop input the RSTC algorithm will begin adapting to account for the roll s diameter and inertia The web must be in mo tion for unwinding applications or in tension for winding applications when this signal goes high otherwise the Adaptive Gain will increase to maximum The RSTC will continue to actively adapt until the encoder pulsing ceases for three seconds At that time the RSTC assumes the machine has stopped and the Adaptive Gain will return to Initial Adaptation Gee OPERATION section The encoder pulse frequency must be in the range of 1Hz to 10 kHz Run SToP COMMUNICATIONS Select this option if the Run Stop signal will be provided by software command over an industrial network After determining the appropriate signal type make a selection from the list of options in the Run Stop Window refer to Figure 19 and press SEND Run Stop Maintained Run Stop Momentary t Pulse Time t must be gt 100ms Run Only Momentary Run Pulsed Encoder Figure 20 FORM NO L 21204 C 0705 TUNING TUNING WINDOW Select the TUNING icon from the toolbar See Figure 21 Note After changing values the SEND key must be pressed
34. the level defined by Splice Adaptation The splice input can be used anytime a new roll is loaded on the machine and the machine can be running or stopped The splice input must be held high for at least 100 ms for the RSTC to detect this signal The adaptation process will begin immediately if the machine is running or will begin after the RSTC receives a Run signal Typically the SPLICE ADAPTATION value is set to the same value as INITIAL ADAPTATION for winding applications During a machine stop Adaptation and Output values will initially increase to overcome a roll s inertia It is normal for the RSTC to remain in Run mode throughout the deceleration and while the web is at zero speed as long as the web tension is capable of being controlled Otherwise the RSTC must go into Stop mode after the web has stopped moving Tapering of the winding tension is possible with the addition of a diameter sensor or signal that can provide a diameter reference for the RSTC Refer to Taper Tension in the TUNING section for more information At the time of the splice the RSTC must receive a Splice A or Splice B signal This will cause the corresponding control output to become the active output that controls the web tension If the new roll is to be controlled by Output B then the splice signal is given to the Splice B input After the splice signal is received the opposite control output goes into standby mode which causes the output to remain at a
35. there is not a Core Diameter in 3 diameter signal therefore the calibration procedure Large Roll Diameter in 50 will not continue 3 Enter the core diameter and large roll diameter Communication that will be used for calibration Core and large roll Calibrate Retrieve Cancel diameters can be representative diameter not the minimum and maximum diameters used on the machine Figure 18 Diameter Calibration 4 Press CALIBRATE and apply the voltage that represents the core diameter to the Diameter Input 5 Press OK and apply the voltage that represents the large roll diameter to the Diameter Input 4 Press OK and the calibration is completed It does not matter if the diameter signal voltage increases or decreases with increasing diameter RUN STOP SIGNAL SELECTION Stop Signal Selectia 1 Note After making a selection the SEND key must be pressed to send the values to the RSTC Run Stop Run Stop Maintained The RSTC determines the run and stop state of a web machine through the Run Stop signal input and was Run Stop Momentary designed to accommodate many different types of run and Run Only Momentary stop machine state signals Run Pulsed Encoder The following figure and descriptions detail the variations Run 2 Stop via Comm of Run Stop signals that the RSTC accepts Communication Run Stop SIGNAL MAINTAINED Retrieve Cancel When the Run Stop input signal is maintained
36. to calibrate the span condition into the SPAN TENSION box Span Tension is equal to the weight as shown in Figure 17 and should be set as close as practical to MAXIMUM SETPOINT 3 Press CALIBRATE 1 4 Unload the tension sensing roller and then press OK The tare condition which is the weight of the roller has just been recorded 5 Load the tension sensing roller as shown in Figure 17 using the amount of web tension entered for SPAN TENSION in step 2 and then press OK 6 Unload the tension sensing roller and then press OK The tare condition is rechecked and the calibration process is completed 15 Close Figure 15 Signal Calibration Calibration Set 1 Span Tension Ib 50 Calibrate 1 Calibration Set 2 Span Tension lb 50 Calibrate 2 Calibration Set 3 Span Tension lb 50 Calibrate 3 xl Tension Minimum Setpoint lb 5 Maximum Setpoint Ib 100 Calibration Set ea Set 2 Set3 Communication Retieve Cancel Figure 16 Tension Calibration Figure 17 For other web paths using the same load cells repeat steps 1 6 for Calibration Set 2 and Set 3 7 select a calibration set to be used select Calibration Set 1 Set 2 or Set 3 and press SEND FORM NO L 21204 C 0705 DIAMETER SIGNAL CALIBRATION F Diameter Calibration 1 Press DIAMETER See Figure 18 Diameter 2 Press Yes if a diameter signal is present and 4 3 continue with calibration Press No if
37. to send the values to the RSTC Gain Adjusts response of RSTC to magnitude changes in tension Higher values cause a more aggressive response and lower values cause a lesser response Stabilization Tunes the tension control algorithm to the natural frequency of the empty core shaft that is being controlled When set properly this parameter allows the gain to be set for best performance TUNING PROCEDURE Most applications will only require adjustment of Gain and Stabilization to tune the RSTC Advanced tuning parameters are available for more demanding applications Note To view diagnostics while tuning select the DIAGNOSTICS icon from the toolbar then select START in the Communication Pane See Diagnostics Section The RSTC features an adaptive algorithm that is user tuned After tuning the algorithm will automatically adapt internal gain values to account for changes in roll diameter and inertia This algorithm is modeled after unwinding and winding applications which results in an non linear adaptation process that closely follows the actual changes occurring in a web machine Stabilization is an important variable that must be set properly for the RSTC to perform correctly If it is set too low Gain will not be able to be set high enough for proper operation and could also cause a high frequency tension oscillation If it is set too high the RSTC could produce a low frequency tension oscillation When tuning it is impo
38. uct Contact Nexen for replacement parts or repair APPENDIX The value of WK is important for applications involving timed cyclic duty or when starting or stopping heavy loads Use one or all of the three methods shown here to estimate the inertia 1 The inertia of solid steel shafting is given in the following table The values given are per inch of shaft length Dia WK Dia WK Dia WK in Ib ft in Ib ft in Ib ft 0 750 0 00006 7 500 0 6110 13 250 5 9600 1 000 0 0002 7 750 0 6990 13 500 6 4200 1 250 0 0005 8 000 0 7910 13 750 6 9100 1 500 0 0010 8 250 0 8950 14 000 7 4200 1 750 0 0020 8500 1 0000 14 250 7 9700 2 000 0 0030 8 750 1 1300 14 500 8 5400 2 250 0 0050 9 000 1 2700 14 750 9 1500 2 500 0 0080 9 250 1 4100 15 000 9 7500 2 750 0 0110 9 500 1 5500 16 000 12 6100 3 000 0 0160 9 750 1 7500 17 000 16 0700 3 500 0 0290 10 000 1 9300 18 000 20 2100 3 750 0 0380 10 250 2 1300 19 000 25 0800 4 000 0 0490 10 500 2 3500 20 000 30 7900 4 250 0 0630 10 750 2 5800 21 000 37 4300 4 500 0 0790 11 000 2 8300 22 000 45 0900 5 000 0 1200 11 250 3 0900 23 000 53 8700 5 500 0 1770 11 500 3 3800 24 000 63 8600 6 000 0 2500 11 750 3 6800 25 000 75 1900 6 250 0 2960 12 000 4 0000 26 000 87 9600 6 500 0 3450 12 250 4 3500 27 000 102 3000 6 750 0 4020 12 500 4 7200 28 000 118 3100 7 000 0 4640 12 750 5 1100 29 000 136 1400 7 25
39. ure 14 Web Material Selection Screen SIGNAL CALIBRATION SIGNAL CALIBRATION WINDOW Select the SIGNAL CALIBRATION icon from the toolbar See Figure 15 TENSION SIGNAL CALIBRATION Set the Maximum Tension Setpoint before calibrating tension sensors Afterwards re calibration of tension sensors is required whenever the Maximum Tension Setpoint is changed Minimum Tension Setpoint Enter minimum tension level that will be run on the machine in the designated imperial or units The choice of units is determined by selecting the DISPLAY icon and then selecting Imperial or Metric in the UNITS pane Maximum Tension Setpoint Enter maximum tension level that will be run on the machine in the designated imperial or metric units The choice of units is determined by selecting the DISPLAY icon and then selecting Imperial or Metric in the UNITS pane NOTE Selection of tension setpoints outside these limits will not be allowed by the RSTC and the Minimum Tension Setpoint will limit taper tension s minimum tension Calibration Set Select Set 1 Set 2 or Set 3 The RSTC allows the use of three different sets of calibration values for converting load cell output voltages into tension values These calibration sets can be used for different web paths that utilize the same set of load cells and have different web wrap angles 1 Press TENSION See Figure 16 2 Under Calibration Set 1 enter the web tension that will be used
40. w impedance connection to earth ground t For improved signal integrity in noisy environments tie cable shields directly to Earth Ground Figure 4 Electrical Connections 7 FORM NO L 21204 C 0705 gt Supplied VDC See Specifications for maximum voltage R See Note To PLC Input VDC Common Le User Supplied NOTE The minimum value of resistor R is 7 x VDC Alarm Output Tied to PLC Input User Supplied External Indicator See Note R VDC See Specifications for maximum voltage wc Common Le User Supplied NOTE The minimum value of Resistor R is equal to VDC divided by the maximum current limit of the Indicator Maximum current limit of the indicator must be less than the current limit of the alarm output See Specifications for maximum current Alarm Output Tied to External Indicator gt User Supplied See Notes RSTO External Coil Alarm Out VDC See Specifications for Alarm l 1N4002 maximum voltage Common VDC Common l L_ User Supplied NOTE Be sure the current requirement of the External Coil does not exceed the capability of the alarm output See Specifications for maximum current Any inductive load such as relay coil must have a 1N4002 or equivalent diode across it as shown Alarm Output Tied to External Inductive Coil To isolate the Alarm Output signals use power supply that is separate from t
41. winder or unwind tension zone For mid process applications select Wind if the controlled nip is downstream of the leader nip and select Unwind if the controlled nip is upstream of the leader nip Refer to Figure 13 Torque Actuator Actuator MOETE Pneumatic Brake Pneumatic Clutch Mag Particle Brake Te Mag Particle Clutch Electric Brake Uhl Electric Clutch Motor Drive System Tancian Actuatd Figure 12 Torque Actuator Selection Screen RSTC Controlled Nip gt Select Unwind RSTC Controlled Nip Load Cell Tension Zone Selection for Mid Process Application Figure 13 FORM NO L 21204 C 0705 ALARMS NOTE A web break is detected whenever the web tension falls below 10 of the Maximum Tension Setpoint Alarm 1 is used to signal the break Tension Tolerance Enter the tolerance 0 100 of the tension setpoint to establish the limits for the High Tension and Low Tension alarms For example if Tension Tolerance is set to 10 and the Tension Setpoint was 100 then the High Tension alarm would be activated if the web tension exceeded 110 and the Low Tension alarm would be activated if the web tension fell below 90 These alarms utilize Alarm 2 to signal their condition Alarm Outputs Select if the alarm outputs are to be normally open NO or normally closed NC A normally open output will close during an alarm condition while a normally closed output will open WEB Max Diameter Enter in the maximu
42. ype B 2 0 USB cable is provided with the RSTC RSTC Communications Software is available by Network Portand download from Nexen s website www nexengroup com Indicators Enter RSTC product number See PART NUMBER Figure 9 section in the product number search window and press Go next select Software from the Accessories menu and finally pick the appropriate software link Instructions for installing the software can also be found here and the instructions for using the RSTC Imperial Communications Software can be accessed in the Help menu Units ROP Language Language English v 1 Connect 24 VDC power supply to Power Input Communication terminals Refer to Figure 4 Retieve Cancel 2 Power up the computer Figure 10 Display Window 3 Connect the USB cable between computer and RSTC Refer to Figure 9 4 Turn on 24 VDC power supply Power indicator will Torque Actuator be on Refer to Figure 9 Actuator Preumatic Brake Actuator Inertia Ib 2 1 Note Refer to the RSTC Communications Software Help menu for instructions on navigating the program and accessing its functions The steps below describe using the functions to configure the RSTC Tension Zone Unwind Wind Alarms L Tension Tolerance 50 i Alarm Outputs NO C NC Select the DISPLAY icon from the toolbar See Figure 10 Web Roll Diameter in 50 Units Select IMPERIAL if tension and diamet
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