RSD250 Web Dancer Controller System 21179
Contents
1. 11 Part NUMDEIS 11 Parts LiSt anne 11 Warranty enee 14 3 FORM NO L 21179 B 1003 CESS Naaza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventasGindustrialmagza com INTRODUCTION The Nexen RSD250 Unwind Dancer Package consists of all the essential components necessary for state of the art dancer arm control This system is designed for unwind applications using a pnuematic brake Included in the kit is a RSD250 controller DPS60 dancer arm position sensor EN50 pressure converter air supply filters and air line tubing The RSD250 controller is housed inside an enclosure that only requires 120 or 240 VAC service to be wired in All DPS60 EN50 and external signal connections are made to the RSD250 via pre wired connectors Additionally all the pneumatic connections are made using tool less quick connect fittings thus connecting components together is fast and easy with little chance of error This system has been pre configured for unwinding applications using pneumatic brakes Essential setup parameters are set so only the DPS60 must be calibrated and the proper Start Sto2. 4 RS D250 O Verview 4 Installation 4 Electrical and Pneumatic C onnections 5 S etup and C alibration 6 Jumper Setting 6 Provide P OWE 6 Calibrate DPS 60 6 Start Stopped Signal Selection 7 TUNING nnn 9 G aN ee nnn nnn nnn eenen eeen eee 10 New Roll Adaptation 10 S pecifications
3. 1003 4 BEES NAGZA MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventas industrialmagza com ELECTRICAL AND PNEUMATIC CONNECTIONS RS D250E User Supplied as AIR SUPPLY FILTER 100 240 VAC 50 60 HZ NEXEN Supply Connections User Supplied Contacts Pressure Output Table 1 Digital Inputs ON OFF Cable Wire Cable Pin wer mii Power Switch ire Start S top Circuit Breaker Poner Ax ower Connections Psi Shield Shield Drain Green Yellow de Figure 2 Table 2 Table 3 DPS60 Din _ Recepticle Connector Receptacle 12 VDC Ground Ground Black 4 Black ET Shield 2 White in 1 3 2 5 3 4 Black E 5 5 FORM NO L 21179 B 1003 CESS Naacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventasGindustrialmagza com SETUP AND CALIBRATION JUMPER SETTING Set W2 to position two factory default This jumper must be in position two before calibrating the DPS60 or tuning the controller PROVIDE POWER Provide 120 or 240 VAC service to the RSD250 that meets local electrical codes See Electrical and Pneu matic Connections section for connection information After providing VAC power turn RSD250 on with circuit breaker disconnect switch S ee Figure 2 C heck the green LEDs I1 and 12 on RSD250 to make sure both are on CALIBRATE DPS60 After installing and connecting the DPS60 dancer arm position sen
4. Start Only Signal Momentary W hen the Start Stopped input signal pulses high the RSD250 algorithm will begin adapting to account for the roll s diameter and inertia The web must be in motion when this signal goes high otherwise the Adaptive G ain will increase to maximum After the machine stops the RSD250 will continue trying to adapt until the Start Stopped input pulses high again and causes the adaptation process to start over Encoder Pulses The first time a machine driven encoder pulses the Start Stopped input the RSD250 algorithm will begin adapting to account for the roll s diameter and inertia The web must be in motion when this signal goes high otherwise the Adaptive G ain will increase to maximum The RSD250 will continue to actively adapt until the encoder pulses cease for three seconds At that time the RSD250 will assume the machine has stopped and the Adaptive Gain will become to a constant value Table 4 Rotary Switch Position Start Stopped Signal 0 Not Used Start Stopped Maintained Start Stopped Momentary Not Used Not Used Determine which signal type your machine uses and set the Rotary Selection S witch Start Only Momentary Encoder Pulses FORM NO L 21179 B 1003 8 INDUSTRIAL TUNING A typical unwind application begins with a new full roll To insure that the dancer arm stabilizes as quickly as pos sible the SPLICE signal can be used to reset adaptation to NEW R
5. of Nexen s Liability TO THE EXTENT PERMITTED BY LAW NEXEN SHALL HAVE NO LIABILITY TO BUYER OR ANY OTHER PERSON FOR INCIDENTAL DAMAGES SPECIAL DAMAGES CONSEQUENTIAL DAMAGES OR OTHER DAMAGES OF ANY KIND OR NATURE WHATSOEVER WHETHER ARISING OUT OF BREACH OF WARRANTY OR OTHER BREACH OF CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE EVEN IF NEXEN SHALL HAVE BEEN ADVISED OF THE POSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE For all of the purposes hereof the term consequential damages shall include lost profits penalties delay images liquidated damages or other damages and liabilities which Buyer shall be obligated to pay or which Buyer may incur based upon related to or arising out of its contracts with its customers or other third parties In no event 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 compe tent 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 na
6. 50 85V with Cable Prefilter amp Coalescing Filter DPS60 With C onnector Nylon Tubing 156 diameter Nylon Tubing 250 diameter 11 FORM NO L 21179 B 1003 CESS Naaza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventasQindustrialmagza com RSD250E RSD250E Basic Enclosure Dome Plug Mounting Panel Enclosure Wire Green Yellow Pan Head Slot Screw 165 32 Terminal Ring 190 Stud RSD250 Assembly 0 pen C over Marker Strip 1 10 Din Rail 35 mm Marker Strip 11 20 End Bracket Red Wire 20 Awg Circuit Breaker 19 Black Wire 20 Awg Terminal Block 20 Pan Head Slot Screw Grounding Terminal Block 21 Rear Mount Receptacle 4 Conductor IDEC Power Supply 24 V Rear Mount Receptacle 5 Conductor Power amp Signal Cable Rear Mount Receptacle Rev Key 5 Cond Shielded Cable 4 Cond Mail Connector FORM NO L 21179 8 1003 12 INDUSTRIAL EN50 85 V WITH CABLE MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Assembly with conn 0 85 psi 1 Shielded Cable Female 3 Conductor 1 25 NPT Salg ng Tube 1 Q HiT sanr 25 be gt PREFILTER amp COALESCING FILTER L Es cnexen N3 Figure 11 13 om a m oO afun YB m oO US X3U DPS60 Assembly with Connector Mounting Bracket Pan Head Machine Scre
7. OLL ADAPTATION before the machine starts This shortens the time it takes for the RSD250 to adapt its gains to the new roll If a SPLICE signal is not used the dancer arm may be Sluggish on the first start with a full roll This is because the adaptation process will begin at a minimum adapta tion value and take longer to reach the optimum gain level Once the RSD250 adapts to the new roll the adaptation process will level off and on subsequent starts the arm will quickly move into position During a run the adapta tion process continually adjusts the gains to account for changes in roll size When the START signal goes high at the Start S topped input the RSD250 will begin adapting The web must begin to move at this instant MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventas industrialmagza com As the roll begins to accelerate the dancer arm will seek its home position O ver time the roll will decrease in size along with RSD250 s output and control gains During constant speeds the dancer arm will remain stable but the output signal will not be steady During a machine stop the adaptation process will increase the RSD250 s output and gains in order to overcome the roll s inertia W hen the RSD250 is in STOPPED mode the adaptation process is halted However the RSD250 s output will still change depending on the dancer arm s position After the next START signal is given the RSD250 adap
8. ON VIVAG ZA MEX 65 53 63 23 31 MTY 81 83 54 10 18 SE DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com nexen WEB CONTROL PRODUCTS User Manual 22 RS D250 Unwind Dancer Package FORM NO L 21179 B 1003 CESS Naacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventasQindustrialmagza com 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 Parkwa Vadnais Heights Minnesota 55127 ISO 9001 Certified Copyright 1999 Nexen Group Inc FORM NO L 21179 B 1003 2 CESS Naacza MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventasGindustrialmagza com Table of Contents IntrOdUCti0N
9. When the machine is at a constant speed allow about ten seconds for the RSD250 to adapt Indicator a Change the machine speed to introduce a Rota dancer arm disturbance The dancer arm will Swit move and return to its operating position quickly with little or no overshoot b Ifthe arm is slow to reach it operating position increase Gain and repeat the test c If dancer arm becomes unstable after a speed change decrease Gain and test again NEW ROLL ADAPTATION New Roll Adaptation is adjusted by rotating a potentiometer R20 on the RSD250 printed circuit board See Figure 6 To increase turn clockwise to decrease turn counterclockwise Adjust New Roll adaptation one turn at a time NEW ROLL ADAPTATION is the beginning adaptation value that the RSD250 will adapt from after receiving a Splice signal The closer this value is to the actual adaptation value the shorter the time required for the RS D250 to adjust itself to actual roll conditions so NEW ROLL ADAPTATION needs to be set for a new roll NOTE If a machine is started with a new roll smaller than the roll used to set NEW ROLL ADAPTATION the controller gain could be too high causing the dancer arm to become unstable Unwind applications begin with new rolls and run them down to their core diameter Some unwind applications start with the same diameter ro
10. ll every time others start with rolls of various diameters NEW ROLL ADAPTATION should be set to the smallest diameter new roll run under minimum tension conditions 1 Load the smallest diameter new roll on the machine and set the web tension to minimum 2 Momentarily apply the splice signal 3 Start the machine and note if dancer arm stabilizes quickly about its operating position 4 Ifarmis unstable or takes an excessive amount of time to settle down then decrease NEW ROLL ADAPTATION If arm is very sluggish to start then increase NEW ROLL ADAPTATION Repeat steps 2 and 4 5 Unwind the roll and check periodically that dancer arm quickly returns to its operating position after each start up as the roll becomes smaller FORM NO L 21179 B 1003 10 CESS Naacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventasQindustrialmagza com SPECIFICATIONS POWET iieii 100 240 VAC 12 VA 50 60 Hz Air SUpply wesc 90 150 psig 630 1050 kPa Temperature RSD250 32 F 140 F 0 C 60 C uit E Air Filter 40 F 120 F 4 C 50 C Digital Inputs 12 24 VDC 24mA maximum PART NUMBERS RSD250 Unwind Dancer Package 964260 RSD Communications Kit 964521 PARTS LIST RSD250 STARTER KIT Digital Inputs 4 RSD250E Controller EN
11. pped signal selected by the installer After the installation is complete the RSD250 is tuned to the application using two potentiometers located on the main control board Other setup and tuning parameters may need to be adjusted to accommodate more demanding applications and the RSD Communications Kit See Part Numbers Section can be purchased separately and used to adjust all param eters RS D250 OVERVIEW As aroll changes diameter a dancer control must adapt to the corresponding changes in speed inertia and torque if high dancer performance is desired High dancer performance not only ensures constant tension it allows for faster machine accelerations and decelerations which means more production on many machines The RS D250 is a truly adaptive controller and will adapt its response to changing roll diameter and inertia condi tions This ensures that the RSD250 will always provide the right amount of action for stable dancer arm performance Other benefits 1 Diameter sensing is not necessary 2 Splicing different size rolls without readjustment 3 Excellent performance at slow web speeds and on small rolls INSTALLATION CAUTION Mount all the RS D250 Basic Dancer Kit components 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 For installation instructions for the EN50 and DPS60 refer to their maintenance manuals included with this kit FORM NO L 21179 B
12. propriate signal set the rotary switch on the RSD250 printed circuit board per Table 4 100 Machine Speed 0 1 Start Stopped Maintained 2 Start Stopped Momentary t Pulse Time t must be gt 100ms 5 Start Only Momentary 6 Encoder Pulses Figure 4 START STOPPED SIGNAL DESCRIPTIONS Start Stopped Signal Maintained W hen the Start S topped input signal is maintained low the RS D250 assumes the machine is stopped When the Start S topped input signal transitions to a maintained high the RSD250 algorithm will begin adapting to account for the roll s diameter and inertia The web must be in motion when this signal goes high otherwise the Adaptive G ain will increase to maximum After the S tart S topped signal transitions back to low the Adaptive G ain will stop adapting and remain a constant value Start Stopped Signal Momentary When the Start S topped input signal pulses high the RSD25 0 algorithm will begin adapting to account for the roll s diameter and inertia The web must be in motion when this signal goes high otherwise the Adaptive Gain will increase to maximum After the S tart Stopped signal pulses high a second time the Adaptive Gain will stop adapting and remain a constant value because the RS D250 assumes the machine has stopped 7 FORM NO L 21179 B 1003 CESS Naacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com
13. sor the next step is to calibrate it 1 Place the dancer arm in the maximum storage position 2 Rotate the rotary switch on the RSD250 to position E See Figure 3 LED I7 will begin blinking after approximately ten seconds it will stay on for two seconds then turn off While the LED is blinking the dancer arm can be moved Once the LED is on continuously the RSD250 will have captured the arm s position 3 Place the dancer arm in the minimum storage position See Figure 3 4 Rotate the rotary switch on the RSD250 to position F See Figure 3 LED I7 will begin blinking after approximately ten seconds it will stay on for two seconds then turn off While the LED is blinking the dancer arm can be moved Once the LED is on continuously the RSD250 will have captured the arm s position FORM NO L 21179 B 1003 6 Indicator Rotary Switch KIL oF O2 OO I2 11 CESS Naacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventasGindustrialmagza com START STOPPED SIGNAL SELECTION The RSD250 determines the start stopped state of a machine through the Start Stopped Signal Input The RSD250 was designed to accommodate many different types of machine state signals The following figure and descriptions detail the variations of Start Stopped signals that the RSD250 accepts After choosing the ap
14. tation will begin adapting again Any time the SPLICE signal is given the adaptation pro cess will be reset to NEW ROLL ADAPTATION This is useful after a web break where the adaptation process could increase the RSD250 s gain too high resulting in an unstable dancer arm at the next machine start It can also be reset to the minimum adaptation value by moving the dancer arm to its maximum storage position while the RSD250 is stopped Large Roll he Rh 4 Small Roll Optimum Gain ee O Adaptation New Roll Adaptation F Min Adaptation Run Speed Start Stopped ae Run Speed Acceleration Deceleration Acceleration NOTE Only GAIN and NEWROLL ADAPTATION can be adjusted via potentiometers on the RSD250 s printed circuit board For access to all RSD250 setup and tuning parameters you must use the RS D Communications Software Kit 9 FORM NO L 21179 B 1003 CESS Naacza MEX 55 53 63 2331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventasGindustrialmagza com GAIN Note Gain must be adjusted first because it affects all tuning parameters and controls how the dancer arm responds to errors Gain is adjusted by rotating a potentiometer R19 on the RSD250 printed circuit board See Figure 6 To increase turn clockwise to decrease turn counterclockwise Adjust Gain one half turn at a time New Roll Adaptation 1 Operate the machine at a slow run speed with a nearly full roll 2
15. ture 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 became apparent nes 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 FORM NO L 21179 B 1003 14
16. w Flat Washer Spring Lock Washer Hex Nut Pan Head Machine Screw Stub Shaft Serial Sticker FORM NO L 21179 B 1003 CESS Naacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 7260 ventasGindustrialmagza com 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 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
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