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1. 24096 2 5 Supply cable output 30 e TG 4H9 120 Magnetic particle brakes BBR5 3 x M5 deeph 8 mm on dia 55 mm equidistant for mounting Supply cable output 91 66 0 1 55 0 1 104 0 1 27 160 31 30 20 40 96 12 g6 i Specifications Models Attention For correct use of the brake the operating temperature must not be more than 70 Models Maximum torque R sistance 20 Residual torque Power dissipation Voltage Weight Current BB12 1 60 3 x M5 deeph 8 mm equidistant for mounting Supply cable output 0103 0 10 0 0 03 955187 0115 49 51 Magnetic particle brakes BBR12 1 Supply cable 3 x M5 equidistant output for mounting M5 103 01 200 55 1063 h7 Specifications Attention For a correct use of the brake the operating temperature must not be more than 70 C Models BBR12 1 BBV12 1 Models BBR12 1 BBV12 1 Maximum torque 12 12 Resistance at 20 C 25 25 Residual torque 0 3 0 3 Power dissipati
2. 005 BC1 20 1 5mm old ref BC120 09254 ons Scale 2 1 2010 0005 0233 010 080 0015 20 001408 0195 010 p lt AG SS ui S 4 7 mm equidistant for mounting Specifications Models BC120 1 BGR120 1 Attention the operating temperature must not be more than 70 C Maximum torque 120 120 Residual torque Voltage Current Resistance at 20 C Power dissipation at 500 RPM Power dissipation at 1000 RPM Weight VIEW A Brushes holder BCR120 1 390 Scale 2 1 215 0 10 I 5mm old ref BCR120 21456 2 4 x 97 mm equidistant for mounting Magnetic particle clutches BCI 0 1 0233 01 0212 01 _ 156 01 10010 d F N m Q m Supply cable output 4 x 7 mm equidistant for mounting 28 H7 MD 22 14 34 80 0 05 _ 19 55 g H 5 7440 1 5 100 8 Specifications Attention the operating temperature must not be more than 70 C Mis Maximum torque Residual torque Voltage Current Resistance at 20 C Power dissipation at 500
3. HMCS2000 CRD2 24 VDC Amplifier 32 35 HMCS2000 DRV2 Brake MPB Controller 38 44 EEE HMCS2000 ECA 0 10 VDC Hand Programmer HMCS2000 PRG HMCS2000 WINO1 programme 22 Automatic setting by dancer arm POWER SUPPLY BTCS252 255 and HMCS2000 DRV2 see page 9 ROTARY SENSOR HMCS605 E2 see pages 20 and 21 CONTROLLER HMCS2000 ECA Digital controller 2 channels Main Characteristics 24 VDC power supply unit piss PID parameters setting on line Automatic adaptation for PID parameters splicing logic included Opto isolation for input and output Compatible PLC Automatic sensor scaling and output sensor information Programming easy by pocket keyboard or PC Windows Available in open loop as calculator 2 analogic input 2 output channels Plugable memory card Three language available Most dedicated for unwinding and rewinding with electromagnetic brakes and clutches Service manual MC514 BTCS232FM RS232 SERIAL CABLE The BTCS232FM cable is specially adapted to connect MCS2000 range controls to PC C Service manual SM374 HMCS2000 PRG HAND PROGRAMMER 4 command keys only 2x16 characters display O Menu in languages 1 Connectable and disconnectable during operation O Supply by control HMCS 2000 EC HMCS2000 CRD2 MEMORY CARD All setting data saved It allows a quick loading operation on new machine or on
4. Energy 0 103 Torque slip 0 103 2 53 375 97 72 watts Select a clutch that exceeds the maximum torque and thermal energy requirements from the Quick Selection Chart MPC120 To maximize tension control and minimize heat generated select a drive system that will result in an actual input speed as close to but not less than 30 RPM greater than the core RPM In this example 358 30 388 would be ideal but 500 RPM was more readily available Magnetic particle brakes MPB F 305 mm p K Both ends l G gt 01 5 Both ends m gt n 3 lt 3 E 4 D Rated current Max heat Inertia of output shaft Models Rated voltage Resistance Response zero force Response with force dissipation VDC A ms ms MPB2M 6 24 MPB15M 12 24 MPB70M 19 24 MPB120M 19 24 MPB240M 24 24 MPB240 007 Dimensions mm Models 24 24 24 24 24 24 92 80 Keyway DIN 6885 Width x length 8 4 25 3 10 90 25 150 45 150 45 0 0037 0 04 0 23 1 09 3 92 3 92 Mounting K 10 20 100 200 200 MPB2M 6 24 MPB15M 12 24 MPB70M 19 24 MPB120M 19 24 MPB240M 24 24 MPB240 007 Models Pilot B 5 5 flat on 16 4 2
5. Power dissipation at 1000 RPM Weight 0390 233 01 212 01 156 01 pe 10 D10 Q le m m 4 equidistant for mounting 128 H7 77 22 5 2254 80 005 9214 2197 66 Magnetic particle clutches BC250 Supply cable 33 286 output 2267 0 1 0 1 100 0 1 16 010 90 0 05 KA EN lt MN a 2 1 2 ND Y M 250 0 1 0 1 055 H7 9267 0 1 0 1 10 80 40 1 14 for mounting Specifications Attention the operating temperature must not be more than 70 C Models BCR250 Maximum torque 250 Residual torque 1 Voltage 24 Current Resistance at 20 C Power dissipation at 500 RPM 11 Power dissipation at 1000 RPM Weight VIEW A Brushes holder 33 BCR250 Supply cable output 250 0 1 267 0 1 408 286 150 h8 17 100 0 1 90 0 05 0 0 063 33 FI 8 x M6 equidistant for mounting 16010 B 259 3 0 2 0 0 55 H7 267 0 1 0 1 Magne
6. fi 9 electrical com DN ponents to fail N for direct mounting Easy to read graduations Torque adjustment ring establishes position of permanent magnets to vary the amount of torque Bolt circles on both ends for versatile mounting SPECIAL APPLICATIONS Specials are our business 1 Special shaft bores and keyways 1 Shaft extensions System retrofits Fixed torque units Stainless steel MC4D Long shaft extension Magnetic brakes MB Specifications Standard models Stainless steel models lt 2 54 MB5 only P 4 WARNER ELECTRIC Model MB E Torque MIN ad CN Max torque Nm Set screw adjustment Max heat dissipation W Inertia of output shaft kgm Drawing C Bending moment Nm MB1M 5 MB2M 6 MB3M 8 MB4M 14 MB4M 15 MB5M 19 MB5M 24 MB5 5M 19 MB5 5M 24 MB6M 19 MB6M 24 MB6DM 24 MB9M 24 MB1MS 5 MB2MS 6 MB3MS 8 MB4MS 14 MB4MS 15 MB5MS 19 MB5MS 24 MB5 5MS 19 MB5 5MS 24 MB6MS 19 MB6MS 24 Dimensions mm Models Drawing 0 0078 0 16 0 68 1 24 1 24 3 4 3 4 5 6 5 6 79 79 15 8
7. 2 600 2 400 200 0 0 0 2 0 5 067 0 9 1 1 1 35 1 58 Torque Nm MPB120 MPC120 1000 Heat dissipation 800 140 watts max 2 c 600 2 400 200 0 0 22 4 51 6 77 9 11 3 13 55 Torque Nm MPB240 1000 Heat dissipation 800 200 watts max 2 2 600 2 400 200 0 4 4 9 13 5 18 22 5 27 Torque Nm Magnetic particle clutches and brakes Applications Warner Electric Precision Tork magnetic particle clutches and brakes are the ideal solution for controlling and maintaining torque If the application is tensioning load simulation torque limiting or soft starts and stops the magnetic particle unit is the preferred torque controlling device Typical Applications Unwind stand under load cell control Wire Processing winding hooking cut ting Paper Foil Film Processing Labelling Applications Textile Processing Load profile simulation on Exercise Equipment Flight Simulators Healthcare Equipment Life testing on Motors Gears Pulleys Rewind stand under dancer control Belts Chains Many other Rotating Devices 1 Conveyors Bottle Capping Magnetic particle clutches and brakes Tensioning Magnetic Particle clutches and brakes offer smooth controlled torque for tensioning in both the unwind zone and rewind zone Torque produced from the magnetic particle clutches and brakes is independent of slip speed o
8. 59 3 0 2 0 0 55 7 250 0 1 267 0 1 2406 267 0 1 90 0 05 18 e o 5 2 o 10 10 UH F gt 8 x M6 equidistant 82 0 1 for mounting 100 0 1 NS 45 o Magnetic particle brakes BBV250 100 0 1 Fan 8 x M6 equidistant 16 0 1 0 0 Brake cable 1 cable for mounting T o 2 2 5 D 55 H7 0 1 267 0 1 Specifications Attention For a correct use of the brake the operating temperature must not be more than 70 C Models BBV250 Models BBV250 Maximum torque 250 Resistance at 20 C 22 Residual torque 1 Power dissipation 2400 Voltage 24 Weight 38 Current Fan tension 24 VDC 115 230 AC BB500 Supply cable 28 output 120 0 1 99 V r 5 16 010 9 5 3 E g CN D 5 915 10 55 7 1 8 x 8 5 mm equidistant for mounting 110 Magnetic particle brakes BBR500 Supply cable output PPY 120501 1 5 S 5 25 9 110 s 88 8 5 8 ID S
9. slip speed RPM In rewind applications the motor RPM should be higher 10 96 than the fastest spool RPM In applications with the web running over a pulley or in a nip roll application use the pulley diameter as the roll diam eter In rewind application don t forget to always mount the motor output to the exterior flange of clutch to enable maximum heat dissipation as drawing below Mounting example for clutches in line W Watts 10000 W Watts 1000 100 10 10000 im B Bd Clutches Series BC e 500 1000 2000 Speed RPM 1000 100 Clutches Series BCR 10 e 500 1000 2000 S peed RPM Magnetic particle brakes Quick selection BRAKES Torque Nm Dissipation W CLUTCHES Torque Nm Dissipation W BB2 35 BC12 12 120 150 BBR2 55 BCR12 12 440 550 BB5 70 BC35 35 200 250 BBR5 160 BCR35 35 640 800 BB12 100 BC65 1 65 280 350 BBR12 200 BCR65 1 65 960 1200 BBV12 400 BC120 120 800 1000 BB35 150 BCR120 120 1600 2000 BBR35 28
10. 1200 600 0 7 2 1 3 5 4 9 6 3 Torque MC4 MB4 1800 1500 Slip RPM 0 0 0 1 0 2 0 3 0 4 0 5 0 6 07 09 1 1 1 Torque Nm MC6 MB6 1800 1500 Slip RPM 8 Torque Nm MC2 MB2 M 2400 2 n 3600 3000 1800 1200 600 0 me MC5 MB5 MC9 MB9 Torque Nm Magnetic clutches and brakes Torque Setting Charts MB1 1 2 3 Unit torque settings MC4 MB4 1 35 Torque Nm 0 67 0 45 0 22 Le 1 2 3 4 Unit torque settings MC6 MB6 Torque Nm 8 5 o 1 2 3 4 Unit torque settings MC2 MB2 Torque Ncm 15 8 12 9 10 72 4 32 1 44 0 0 2 3 4 5 Unit torque settings MC5 MB5 Torque Nm Unit torque settings MC9 MB9 Torque Nm 33 9 28 2 22 6 17 11 5 6 0 1 2 3 4 5 Unit torque settings MC3 MB3 2 3 4 Unit torque settings MC5 5 MB5 5
11. Specifications all HFM series Power supply 12 to 15 VDC 5 or 10 VDC Sensitivity 0 5 VDC nominal load 10 mV nominal load Rating 100 250 500 1000 2500 5000 10000 Connections Cable supplied Permitted overload Compression 150 Extension 120 Radial permitted force 50 Dimensions See mounting instructions ref MC480 Mounting See recommendations on page 29 Service manual MC480 AVAILABLE MODELS CAPACITY Nom load 1000 2500 5000 10000 1 1000 2500 5000 HFMO01A 1000 C 2500 C 5000 HFM02 5000 AC 10000 AC HFM02 5000 C 10000 HMCS2000 IS Load Cell Interface The interface sensor will sum and amplify the input signals from two load cells and can be used with number of different load cells The interface should be positioned close to the load cells to ensure that no noise is injected into the low voltage signal before it is amplified Specifications Input power Output power Input supply 24 VDC 10 300 mA Analog outputs short circuit protected Analog inputs Calibrated load cell 2 load cell input any voltage between 20 mV and ultrasonic sensor output 0 10 VDG 10 mA max 10 VDC 5 input impedance Power for ultrasonic sensor 24 VDC Ultrasonic input 0 10 VDG delta mon of 1 V Voltage reference 10 VDG 10 mA 10 input impedance Service manual MC521 max gain 10
12. Torque Nm 5 6 45 3 3 2 2 2 3 Unit torque settings 4 Applications Unwind tension control Information required Full roll m 0 15 core 0 1 Average tension 18 Velocity m mn 30 Brake mounted on shaft of unwinds spool or bobbin How to size Average radius Full roll core 4 0 15 0 1 4 0 06 Check tension range Max tension Torque 2 core 1 08 2 0 1 21 6N Min tension Torque 2 full roll 1 08 2 0 15 14 4 Slip watts watt Max tension velocity 60 21 6 30 60 10 8 watts Film unwind Tension provided by hysteresis units Average tension Nm Average tension Average radius 18 0 06 1 08 Nm Select MB4 Model Select an MC4 Model from the specification chart Information required Slip 500 tr mn Clutch Torque 0 90 Nm slip time of total cycle time 25 Consult factory if peak slip watts are extremely high or if duration of slip period is in excess of 1 minute Bottle capping Constant torque provided by a hysteresis clutch How to size Torque slip 955 500 0 9 995 Watts uS 9 55 9 55 11 8 watts Information required Pulley or nip roll diameter 0 1 m Tension 26 N Velocity 30 m mn Brake How to size Torque Tension 2 26 0 1 2 1 3 Nm Coil winding Slip watts max ten
13. ae E 24 vr e 07 7 DAR y 77 Tension Control Systems Warner Electric Tension Control Systems WARNER ELECTRIC offers the most complete product line dedicated to the TENSION CONTROL MARKET The long experience in the market led us to develop high performance controls able to operate in open and closed loop with brakes WARNER ELECTRIC electromagnetic brakes find an optimum use in tension control when associated with the new digital control line ABOUT THIS CATALOGUE This master catalogue groups all the solutions products that WARNER ELECTRIC offers An important part is dedicated to the solution design with particular consideration regarding the machine and the tension control installed This should help you for the right solution choice taking in consideration the results you want to achieve All the product characteristics and dimensions are included for every product Applying the appropriated Tension Control will lead you E To improve quality of the operation To increase the production Finally to lower your production cost CONTACT WARNER ELECTRIC FOR ANY ASSISTANCE YOU REQUIRE www warnerelectric eu com 9 A 1 SYSTEM CONFIGURATIONS System configuration 1 System configuration 2 System configuration 3 Open loop solutions Closed loop solutions TENSION CONTROL IN OPEN LOOP Manual setting by pot lb
14. 233 0 1 212 0 1 80 0 5 10010 IS 8 28 7 4x87 mm equidistant for mounting Supply cable output 0 1 90 01 Specifications Attertion For a correct use of the brake the operating temperature must not be more than 70 Mois Mois BBDO 1 Maximum torque Resistance at 20 1 Residual torque Power dissipation 2000 Voltage Weight 28 Current Fan tension 24 VDC 115 230 AC BBVIO 180 Brake cable 0284 023350 Fan cable 254 214 197 31 3 0 1 0 0 4 x 7 mm equidistant for mounting 58 Magnetic particle brakes BB250 Supply cable output 0 T 286 0 063 267 0 1 16 D10 150 h8 10 10 55 H7 250 0 10 0 10 80401 5 8 x M6 equidistant 267 0 1 0 1 100 0 1 for mounting Specifications Attention For a correct use of the brake the operating temperature must not be more than 70 C Models BBR250 Models BBR250 Maximum torque 250 Resistance at 20 C 22 Residual torque 1 Power dissipation 1200 Voltage Current 24 Weight 38 BBR250 Supply cable output
15. D 240 i Material length spillage v t 120 Subject to alteration without prior notice secondes secondes secondes secondes Nm secondes metres Newtons Newtons Nm secondes metres secondes metres 0 if MB not defined 0 if MB not defined 1 not defined Industrial Motion Altra Industrial Motion Inc 14 Hayward Street Quincy MA 02171 U S A Tel 01 617 328 3300 Fax 01 617 689 6202 EUROPE FRANCE WARNER ELECTRIC EUROPE Si ge social et usine 7 rue Champfleur BP 20095 F 49182 St Barth lemy d Anjou Cedex T l 33 0 2 41 21 24 24 Fax 33 0 2 41 21 24 00 e mail sales dept Qwarnerelectric eu com ASIA HONG KONG P R CHINA WARNER SHUI HING Ltd Unit 4A 3rd Floor Join In Hang Sing Centre 71 75 Container Port Road Kwai Chung Hong Kong Tel 852 2615 9313 Fax 852 2615 9162 INDIA M s FRANCIS KLEIN amp Co Pvt Ltd 70 1 Mission Road IND Bangalore 560 027 Tel 91 802 272781 Fax 91 802 276324 KOREA SINGAPORE WARNER ELECTRIC SINGAPORE 30 Pioneer Road Singapore 628502 Tel 65 487 4464 Fax 65 487 6674 TAIWAN WARNER ELECTRIC Ltd 3rd FI No 35 Lane 32 Kwang Fu South Road 105 Taipei TAIWAN R O Tel 886 2 2577 8156 Fax 886 2 2570 6358 THAILAND WARNER ELECTRIC Co Ltd 199 19 Soi Anamai Srinakharin Rd Prawes Bangkok 10250 Thailand Tel 66 2 322 0481 Fax 66 2 320 2380
16. Scale 2 1 Specifications Attention For a correct use of the brake the operating temperature must not be more than 70 C Models BB120 1 BBR120 1 Models BB120 1 BBR120 1 Maximum torque 120 120 Resistance at 20 C 1 1 Residual torque 0 6 0 6 Power dissipation 400 800 Voltage 24 24 Weight 18 23 Current BBR120 1 5mm Old ref BBR120 4 x 27 mm equidistant 0390 73 010 for mounting Scale 2 1 0233 0 10 E 58 0 10 021406 Supply cable output Scale 2 1 Magnetic particle brakes BBV120 1 219 023 E Scale 2 1 0214 d 0195 0 10 5mm old ref BBV120 4 x 7 mm equidistant Supply cable for mounting Scale 2 1 output Specifications Attertian For a correct use of the brake the operating temperature must not be more than 70 C Miis MxHs Maximum torque Resistance at 20 C Power dissipation Residual torque Weight Voltage Current Fan tension 24 VDC 115 230 AC BBI O 1 0233 01 0212 01 0254 0214 2197 099 h8 31 3 0 1 0 0 Supply cable output 4 mm equidistant for mounting 5 74201 5 90 57 Magnetic particle brakes 170 1
17. 184 1 247 60 0 025 P for screw 00 005 eS for screw T eU Reverse mounting of taperlock bushing is possible 35 Tension brake for strapping machine Specially designed for strapping machine the electromagnetic brake TBM10 is adjustable for the different kind of plastic film Mounted on the intermediate roller it will tighten the plastic film and will permit perfect strapping TBM BRAKE OG EN PLASTIC FILM ROLLER TBM SIZE 10 Heat dissipation torque Brake torque mnm n rpm 36 Tension brake for strapping machine TBM SIZE 10 3 pins on 57 96 Keyway according to ISO R773 BS 4235 NFE 22175 tolerance P9 D min 8 mm with standard keyway D min 13 mm with standard keyway U max 24 VDC P 20 C 10 8 Watts Part TBM SIZE 10 Inductor 24VDC Armature VARO3 Hub prebored 27 5 Hub 212 H8 Keyway 4 P9 Armature VARO4 B6650 631 000 39 B110 0000 1358 B540 0000 2519 B540 0000 2517 6650 111 000 08 37 Magnetic particle clutches and brakes Accurate torque control with instantaneous engagement Warner Electric Precision Tork magnetic particle clutches and brakes are unique because of the wide operating torque range avail able Torque to current is almost lin ear and can be controlled very accu rately The unique features o
18. LEN 1 91 110 0 1 8 x 28 5 mm equidistant for mounting Specifications Attention For correct use of the brake the operating temperature must not be more than 70 Models BBR500 BBV500 Models BBR500 BBV500 Maximum torque 500 500 Resistance at 20 2 2 Residual torque 1 1 Power dissipation 3200 4800 Voltage 24 24 Weight 62 62 0 9 0 9 Fan tension 24 VDC 115 230 AC BBV500 213 5 120 0 1 8 x 98 5 mm equidistant Brake for mounting 0360 342 0 1 0 1 2390 Magnetic particle clutches BC12 60 25 0 1 52 5 17 24 3 x M5 equidistant for mounting gt 115 55 h7 103 20 1 163 15H7 41 13 Specifications Attention the operating temperature must not be more than 70 C VIEW A Brushes holder Models Maximum torque Residual torque Voltage Current Resistance at 20 C Power dissipation at 500 RPM Power dissipation at 1000 RPM Weight 60 5 0 1 24 BCR12 1 I N ej gt Q 1 53 3 x 5 equidistant for mounting Magnetic particle
19. Manual setting by following arm l Automatic setting by diameter reading Automatic setting by diameter reading with additional functions TENSION CONTROL IN CLOSED LOOP Single roll tension control automatic setting by dancer arm l Double roll tension control automatic setting by dancer arm modular I Double roll or splicer tension control automatic setting by dancer arm compact IV Double roll or splicer tension control automatic setting by load cells BRAKES AND CLUTCHES RANGE Brakes and clutches models ELECTROMAGNETIC BRAKE TYPE TB Tension brake sizing TB brake characteristics Tension brake for strapping machine MAGNETIC PARTICLE CLUTCHES AND BRAKES MPB MPC Series BB BC Series MAGNETIC CLUTCHES AND BRAKES MB MC Series Applications DATA APPLICATION FORM Tension selection Data application form Index Pages 100 A 8 9 8 9 10 11 12 15 16 16 21 22 23 24 25 26 29 30 30 32 31 32 35 36 37 38 38 45 46 68 69 69 75 76 77 77 78 79 System configurations Analysing and preparing a project in tension control requires good analysis support The general block diagrams below are a good representation of any machine generally supporting tension control We recommend using these diagrams or a part of it in any discussion and correspondence in order to be clear and to avoid possible misunderstandings The tension area in an unwinding system is defin
20. 12 24 28 59 28 56 MPC70M 19 24 41 29 41 26 MPC120M 19 24 62 01 61 99 Magnetic particle clutches and brakes The magnetic particle unit combines the resilience of a fluid coupling with the locked in stability of a friction clutch Torque is transmitted by a spe cially alloyed dry ferromagnetic pow der it apparent viscosity may be changed by modulation of the field coil current The units can sustain continuous slip under maximum heat ratings at a pre cise and stable torque value which is determined by excitation level Slip between input and output mem bers is not necessary in order to trans mit torque and provided load torque does not exceed the torque for which a unit is excited to transmit locked in synchronous operation will take place Conversely if load torque exceeds the energised torque level slip will occur in an absolutely smooth manner at the predetermined torque value For all practical purposes static and dynamic coefficients of friction are sensibly equal also output torque is indepen dent of speed or slip speed Powder performance is unaffected by temperature rise on the working sur faces and units will have at all times a torque directly proportional to current Operating characteristics It should be noted that use of a dry powder rather than a fluid suspended powder medium promotes consistency and accuracy of torque control Briefly the unit include
21. 3 x M6 on 73 03 equidistant M5 3 x M6 on 100 equidistant M5 3 x M6 on 73 03 equidistant M5 3 x M6 on 100 equidistant M5 3 x M6 on 73 03 equidistant M5 3 x M6 on 100 equidistant M5 3 x M6 on 73 03 equidistant M5 3 x M8 on 101 6 equidistant 6 4 x M6 on e 149 23 equidistant M5 3 x M6 on 10795 equidistant M5 MC5 5M 19 MC6M 16 MC6M 19 MC6DM 19 MC9M 24 0 000000909000 03 00 OQ Typical mounting M Stub shaft adapter I 1 I T LL lt gt Flexible coupling Brake Clutch Clutch coupling Typical setup for tensioning wire film and Typical setup for material handling soft starts Typical setup for torque limiting protection fibers and torque limiting used for labeling capping and printing appli cations Magnetic clutches and brakes Heat Dissipation Charts Continuous operation 0 07 0 2 0 35 05 06 08 09 Torque MC3 MB3 0 0 11 0 22 Torque Nm 0 33 0 45 MC5 5 MB5 5 0 05 1 1 16 22 28 34 39 45 5 Torque Nm Intermittent operation 50 duty cycle MC1 5 MB1 5 3600 3000 M 2400 1800 Slip
22. 90 264 VAC 32 35 Brake MPB BB Amplifier Power supply BTCS252 255 Q E e o lt and 0 10 VDC OPTION for HMCS2000 DRV2 HMCS2000 DRV2 BTCS252 Numeric control 12 or Power supply 24VDC 0 10 VDC Automatic setting by diameter reading Ultrasonic sensors Dimensions see page 11 Model HSCUA 130 HSCUA 140 Power supply 15 to 30 VDC max 30 mA 15 to 30 VDC max 30 mA Min distance 100 mm 400 mm Max distance 900 mm 2400 mm NC 2 N Accuracy 1 mm 1 mm SS Protection class IP67 IP67 HSCUA 130 HSCUA 140 Accessory 5 m cable 5 m cable Service manual MC487 MC488 Ultrasonic Diameter Sensing HMCS2000 POT 00 A simple analogue open loop torque control Power supply 24 VDC Internal consumption 150 mA Adjustable maximum level of the output signal relatively to the ultrasonic input level Graphic display of the output level full screen equal 10 VDC FAST STOP HOLD and BRAKE OFF can be activated either through the front switches or through the terminal bloc FAST STOP and HOLD levels are adjustable via potentiometer FAST STOP a ratio of 1 to 10 times to OPERATING LEVEL OUTPUT VALUE 0 100 WEB TENSION ADJUST 1 OPERATING LEVEL maximum 10 VDC divided by the FAST To be used ONLY with scalable ultrasonic sensors type HSCUA 130 Width 95 mm 0 9 m or HSCUA 1
23. clutches BC35 56 0 05 135 5 55 h7 2 5 61 4 0 1 Gs E 55 es N 3 x 5 equidistant for mounting Specifications Attention the operating temperature must not be more than 70 C Models Maximum torque Residual torque Voltage Current Resistance at 20 C Power dissipation at 500 RPM Power dissipation at 1000 RPM Weight VIEW A Brushes holder BCR35 60 56 0 05 33 5 17 5 135 0557 61 4 01 3 5 equidistant for mounting 91223 2240 Magnetic particle clutches 75 5 5 at 120 for mounting Specifications Attention the operating temperature must not be more than 70 C VIEW A Brushes holder Models Maximum torque Residual torque Voltage Gurrent Resistance at 20 Power dissipation at 500 RPM Power dissipation at 1000 RPM Weight BCR65 1 0278 0144 010 at 120 for mounting Magnetic part icle clutches Scale 2 1
24. essential These units comply with the parameters set out by the Low Voltage Directive The low working temperature at full power operating temperature combined with the use of first quality components ensure high reliability and duration Specifications Input 90 264 110 VDC 50 60 Hz Output 24 VDC BTCS252 and 5 BTCS255 Service manual MC550 ELECTRICAL AMPLIFIER HMCS2000 HMCS2000 DRV2 1 logic card with 2 individual channels Model Electrical Power supply Output voltage input signal current current HMCS2000 DRV2 0 10 VDC 24 48 VDC 0 24 48 VDC 4 5 Wiring Shielded cable Setting Anti residual Mounting position Vibrations free vertically Service manual MC517 NUMERIC CONTROL BTCS251 see page 17 Service manual mounting with Pot SM563 BTCS254 06 6 mm axis Dimensions mm BTCS254 10 10 mm axis Potentiometer 10 k Ohm Shaft material Stainless steel 2 AISI3003 Cover material Plastic reinforced with glass fibre g Body material Alu UNI 9002 5 5 Protection Standard IP54 2 Operating temperature 0 60 042 Cable length 15m Weight 150g Service manual MC554 Dimensions mm Dimensions mm 75 174 165 potentiometer BTCS254 is suitable for open or closed loop 4x M3x90 55 183 149 Il Tension control open loop MAIN APPLICATIONS ADVANTAGE Setting type Where When Why Ad
25. the connector Old kit 3 wires New kit 4 wires Cable length 10r2 Compatibility connectors HMCS KIT1 HMCS KIT1A 3m 2 HMCS202 E1 HMCS2000 ECA CTDA HMCS KIT2 HMCS KIT2A 3m 1 HMCS KIT3 HMCS KIT3A 4 5 2 HMCS202 E1 HMCS KIT4 HMCS KIT4A 4 5 1 HMCS2000 ECA CTDA HMCS KIT7 HMCS KIT7A 6m 2 HMCS202 E1 HMCS KIT8 HMCS KIT8A 8m 1 HMCS2000 ECA CTDA ELECTRICAL CONNECTIONS A New kit SIGNAL 1 OV 2 15VDC 0 3 15VDC 4 MALE CONNECTOR i FEMALE CONNECTOR Front view Front view 15VDC OV 3 PRAE 000078 01200000 lt YELLOW SIGNAL 1 18 15VDC 4 MALE CONNECTOR FEMALE CONNECTOR Front view Front view 21 Il Double tension control closed loop modular HMCS2000 ECA is a digital controller that can be used in both open or closed loop Operation in open and closed loop is also possible It is mainly destined for OEM application The programming tool is detachable Sensor sensor mounting kit display are available as options The unit has to be powered with 24 VDC MAIN APPLICATIONS ADVANTAGE Setting type Where When Why Advantage Dancer arm Printing machines O Absorb tension peak Intermittent function Can act as store Flying splice need Easy flying splice Accel decel machine phase well absorbed O Flexibility Sensor HMCS605 E2 2021 Dancer
26. the parameters set out by the Low Voltage Directive The low working temperature at full power operating temperature combined with the use of first quality components ensure high reliability and duration Specifications Input 90 264 110 VDC 50 60 Hz Output 24 VDC BTCS252 and 5 BTCS255 Service manual MC550 ELECTRICAL AMPLIFIER HMCS2000 Dimensions mm HMCS2000 DRV2 1 logic card with 2 individual channels Wii 188 En qw Model Electrical Power supply Output voltage x 9 9 input signal current current E HMCS2000 DRV2 0 10VDC 24 48 VDC 0 24 48 VDC 4 5 A Wiring Shielded cable d Setting Anti residual Mounting position Vibrations free vertically Service manual MC517 NUMERIC CONTROL BTCS251 see page 17 Service manual mounting with ultrasonic sensor SM564 11 Ill Tension control open loop MAIN APPLICATIONS ADVANTAGE Setting type Where When Why Advantage Diameter reading 1 The most commonly used solution in open loop Operator intervention admitted Large roll e ratio Physical reading no reset Easy to start up 1 Graphic display for output percentage value Functions control available remote manually by operator Ultrasonic sensor signal 0 10 VDC Ultrasonic sensor go dD Y EN gt p TB 0 24 VDC
27. to internal correction Typical PID values for TB brakes I Tension control open loop Working in open loop requires that a torque setting is defined The choice depends on the machine complexity and the automation required One important factor that remains is the tension precision For unwind and rewind systems the diam eter ratio will play an important role Working in open loop also requires special considerations regarding system inertia a Manual setting by pot b Manual setting by following arm MAIN APPLICATIONS ADVANTAGE Setting type Where When Why Advantage Diameter Cable machine Low cost solution reading 1 No fast accel deccel Easy to start up 1 Low roll diameter ratio Automatic regulation by diameter Operator intervention admitted following arm O Manual correction feasible Power supply BTCS252 255 r 90 264 VAC e 24 VDC and Pot BTCS254 06 10 0 24 VDC 0 10 VDC Brake TB 32 35 Brake MPB BB Amplifier HMCS2000 DRV2 db 0 10 VDC Numeric control BTCS251 Manual setting by Pot Potentiometer BTCS254 With strong housing and axis with bearing the applications BTCS 252 255 Single phase power supply 24 VDC The Warner Electric switching power supply units of the BTCS252 series are designed and developed for industrial uses where safety ease of use and reliability are
28. two concentric members the body or input member containing the field coil and within it and separated by a small annular gap an inner rotor or output member The annular gap contains a ferromagnetic powder which is activated when the coil is energised The resultant flux which is generated passed through the pow der causing it to align with the flux path and thereby creates a driving bond between input and output members the strength of which is only determined by the value of DC current applied to the coil Torque Da Nm Absorption A The torque transmitted by powder units is proportional to field cur rent and is infinitely variable from maximum design rating down to practically zero in all models Torque current characteristic curves can vary by 5 dependent on whether current is increasing or decreasing This is due to magnetic hysteresis For all practical purposes torque is independent of speed either with or without the presence of slip and can be maintained within an accu racy of 5 for speeds within the recommended operating range 50 to 2600 RPM De energised drag torque due to residual iron circuit magnetism bear ing and seal friction is less than 1 of design torque rating for any unit Response time to torque is determined by field coil inductance to resistance ratio plus a magnetic delay due to eddy current loss Note to ensure satisfactory op
29. x M6 on 73 3 equidistant M5 MB5 5M 24 8x 25 3 x M6 on 100 equidistant M5 MB5 5M 24 8x 25 3 x M6 on 73 3 equidistant M5 MB6M 19 6x25 3 x M6 on 2 100 equidistant M5 MB6M 19 6x25 3 x M6 on 73 3 equidistant M5 MB6M 24 8x25 3 x M6 on 100 equidistant M5 MB6M 24 8x25 3 x on 73 3 equidistant M5 MB6DM 24 8x25 3 x M8 on 2 101 6 equidistant MB9M 24 8x25 4 x M6 149 23 equidistant M5 MB9M 24 8x25 3 x on 10795 equidistant M5 Magnetic clutches gt 2 54 only gt lt 2 amp o 1 x a 5 EM uj b A Da D c ui 871 zZ lt 272 8 5 8 ale 5 z 5 Set screw adjustment gt Drawing Specifications Standard models Stainless steel models Max heat dissipation W Inertia of output shaft Bending moment Nm MC2M 6 MC3M 8 MC4M 8 MC4M 14 MC4M 15 MC4M 16 MC4M 001 MC5M 16 MC5M 19 MC5 5M 16 MC5 5M 19 MC6M 16 MC6M 19 MC6DM 19 MC9M 24 Dimensions Models MC2MS 6 MC3MS 8 MC4MS 8 MC4MS 14 MC4MS 15 MC4MS 16 MC4MS 001 MC5MS 16 MC5MS 19 MC5 5MS 16 MC5 5MS 19 MC6MS 16 MC6MS 19 mm Drawing 10 18 22 22 22 22 22 72 72 110 110 150 150 300 345 4 9x 10 6 4 6 x 109 9 4 x 109 9 4 x 10 9 4 x 10 9 4 x 109 1 7 10 4 5 4 x 104 5 4 x
30. 0 6 x 25 4 6 x 25 4 8 25 4 27 flat on 31 8 3 x M4 on 34 equidistant 3 x M5 on e 51 equidistant 4 x M5 on 107 equidistant 4 x M6 on e 122 equidistant 4 x M6 on 2 149 equidistant 4 x M6 on 2 150 equidistant MPB2M 6 24 MPB15M 12 24 MPB70M 19 24 MPB120M 19 24 MPB240M 24 24 MPB240 007 19 05 28 59 41 29 41 29 62 01 62 01 19 03 28 56 41 26 41 26 61 99 61 99 Magnetic particle clutches MPC 305 Both ends n 0 EEE 5 Both ends 5 ii gt 2 2 22 Li 3 z Y E lt D gt gt Specifications Models Rated Resistance Rated Response Response Inertia of Max heat voltage current zero with output shaft dissipation force force ms ms W MPC2M 6 24 24 92 8 0 0039 10 MPC15M 12 24 24 80 25 0 043 20 MPC70M 19 24 24 35 10 0 26 100 120 19 24 24 33 90 11 Dimensions mm Models Shaft Keyway DIN 6885 Mounting I h7 Width x length K MPC2M 6 24 6 5 5 flat on 16 3 x M4 on 34 equidistant MPC15M 12 24 12 4 20 5 51 equidistant MPC70M 19 24 19 6 x 25 4 4 x M5 on 107 equidistant MPC120M 19 24 19 6 x 25 4 4 x M6 on 122 equidistant Models Pilot B MPC2M 6 24 19 05 19 03 MPC15M
31. 0 BC170 1 170 1000 1250 BBV35 600 BCR170 1 170 2200 2750 BB65 1 170 BC250 250 1440 1800 BBR65 1 400 BCR250 250 2600 3250 BBV65 1 800 BC500 500 2250 3500 BB120 1 400 BCR500 500 4480 4800 BBR120 1 800 BBV120 1 1600 BB170 1 500 XXR Radiator 1 70 1 1000 XXV Fan BBV170 1 2000 BB250 600 BBR250 1200 BBV250 2400 BB500 1600 BBR500 3200 BBV500 4800 BB2 2z 59 36 5 22 5 M 20 2 1 o ae 115 o 88 5 2 un m Q 3 xM4 deeph 8 mm equidistant for mounting Supply cable output 51 5 pecifications For a correct use of the brake the operating temperature must not be more than 70 C Mois Mois Maximum torque Current Power dissipation Resistance at 20 C Voltage Weight 49 Magnetic particle brakes BBR2 79 3 59 36 5 22 5 20 8 bd 8 7 8 xv 2 Je 11 5 8 ee EE 5 8 8 D 1 UUUUUU 3 x M4 deeph 8 mm equidistant for mounting Supply cable output 051 Specifications Attention For a correct use of the brake the operating temperature must not be more than 70 C Models Models Maximum torque Current Power dissipation Resistance at 20 C Voltage Weight BB5 104 50 1 1 091 m 45 28 31 2 66 0 1 21 055 0 1 3 x 5 deeph 8 mm on dia 55 mm 20 5 L equidistant for mounting
32. 00 3 inputs for line speed 0 10 VDG 10 K Q impedance 28 Load cells END SHAFT LOAD CELLS are normally used in new machines designed with the possibility to place the load cell directly on the sensing roll The end shaft version offers the advantage of being able to easily place the load cell in any tension resultant direction The HES model exists in two versions differenciated with the diameter of ball bearing which has to be placed in All end shaft load cells are based on the Wheatstone bridge principle They have no built in amplifier They are delivering signal which is proportionnal to the voltage supply and tension applied It is important to respect the measurement direction referenced on the load cell body normally an arrow indicates the sensitive direction HES LOAD CELL FEATURES HES01 40C and HES02 52C Power supply 10 to 15 VDC 40 mA 5 VDC in Warner Electric control Sensitivity 2 mV V supply at nominal load 1 mV V supply for 50 and 150 models Rating 50 150 250 500 1000 2000 N Connections 5 m shielded cable supplied Mechanical overload Max 150 in any direction Dimensions See mounting instructions ref MC481 and MC482 Mounting See recommendations below Service manual MC481 and MC482 AVAILABLE MODELS CAPACITY Nominal load 150 250 N 500 1000 N 2000 HES01 150 40C 250 40C 500 40C 1000 40C 2000 40C HES02 52501526 500 52 1000 52 2000 52C
33. 10 4 8 5 x 104 8 5 x 104 1 44 x 103 1 4 x 103 2 5 x 103 19 x 103 0 56 1 1 1 1 1 1 1 1 1 1 1 1 2 82 2 82 2 82 2 82 2 82 2 82 2 82 5 65 Pilot H MC2M 6 MC3M 8 MC4M 8 MC4M 14 MCAM 15 MCAM 16 MC4M 001 MC5M 16 MC5M 19 MC5 5M 16 MC5 5M 19 MC6M 16 MC6M 19 MC6DM 19 MC9M 24 0 gt gt gt gt gt gt gt gt gt gt gt UJ Drawing on request 22 25 22 30 35 08 35 13 47 04 47 09 47 04 47 09 47 04 47 09 47 04 47 09 47 04 47 09 61 98 62 00 61 98 62 00 61 98 62 00 61 98 62 00 61 98 62 00 61 98 62 00 82 50 82 55 82 50 82 55 Magnetic clutches MC E Ee F 2 Both ends i 10 31mm x 787mm deep 2 holes 180 apart both ends 4 57 TYP A 5 1 H 3 Hi 33 Spanner wrench adjustment Drawing B Dimensions mm Models Keyway Mounting Adjust Width DIN 6885 1 screws MC2M 6 Roll 3 mm 3 x M4 on 32 equidistant M3 MC3M 8 2 x M4 90 3 x M4 on 48 equidistant M4 MC4M 8 7 5 Flat 3 x M5 on 60 33 equidistant M4 MC4M 14 3 x M5 on 60 33 equidistant M4 MC4M 15 3 x M5 on 60 33 equidistant M4 MC4M 16 3 x M4 60 equidistant M4 MC4M 001 3 x M5 on 60 equidistant M4 MC5M 16 3 x M6 on 80 equidistant M5 MC5M 19 3 x M6 on 80 equidistant M5 MC5 5M 16 3 x M6 on 100 equidistant M5
34. 33 9 25x107 6 3 x 106 4 9 x 10 9 7 x 109 9 7 x 10 5 8 x 104 5 8 x 104 8 8 x 104 8 8 x 104 1 44 x 108 1 4 x 103 25 103 19 103 0 11 0 56 1 13 1 13 1 13 2 82 2 82 2 82 2 82 2 82 2 82 2 82 5 65 Pilot o MB1M 5 MB2M 6 MB3M 8 MB4M 14 MB4M 15 MB5M 19 MB5M 24 MB5 5M 19 MB5 5M 24 MB6M 19 MB6M 24 MB6DM 24 MB9M 24 Drawing on request 10 01 10 06 22 25 22 30 35 08 35 13 47 04 4709 47 04 4709 61 98 62 00 61 98 62 00 61 98 62 00 61 98 62 00 61 98 62 00 61 98 62 00 82 50 82 55 82 50 82 55 Magnetic brakes Both ends 10 31mm x 787mm deep 2 holes 180 apart both ends gt WARNER ELECTRIC Model MB6 Torque 1 65 Ib in Spanner wrench adjustment Drawing D Dimensions mm Models Keyway DIN 6885 Mounting Adjust Width x length I screws MB1M 5 4 5 Flat on 10 2 3 x 15 5 equidistant M3 MB2M 6 5 5 Flat on 19 3 x M4 on e 32 equidistant M4 MB3M 8 7 5 Flat on 22 4 3 x M4 on 48 equidistant M4 MB4M 14 5 19 3 3 x M5 on 60 equidistant M4 MB4M 15 5x 19 3 3 x M5 on 60 equidistant M4 MB5M 19 6 x 25 3 x M6 on 80 equidistant M5 MB5M 24 8x 25 3 x M6 on 80 equidistant M5 MB5 5M 19 6 x 25 3 x M6 on 100 equidistant M5 MB5 5M 19 6 x 25 3
35. 40 2 5 m Depth 75 mm Weight 0 350 kg C Service manual MC520 STOP ratio Mounting and dimensions mm HOLD output level adjustable between 0 and 10 VDC Overall dimensions maximum Height 160 mm 183 149 ELECTRICAL AMPLIFIER HMCS2000 Dimensions mm 75 HMCS2000 DRV2 1 logic card with 2 individual output channels EEE Model Electrical Power supply Output voltage input signal current current HMCS2000DRV2 0 10 VDC 24 48 VDC 0 24 48 VDC 4 5 Wiring Shielded cable Setting Anti residual L gg Mounting position Vibrations free vertically Service manual MC517 POWER SUPPLY BTCS252 255 see page 15 NUMERIC CONTROL BTCS251 see page 17 Service manual mounting with 0 10 V signal SM571 13 Ill Tension control in open loop MAIN APPLICATIONS ADVANTAGE Setting type Where When Why Advantage Diameter reading The most commonly used Physical reading no reset solution in open loop Easy to start up Operator intervention admitted Particle brake current controled Large roll e ratio Cheaper solution Ultrasonic sensor Ultrasonic sensor signal 0 10VDC or Pot 10 K Ohm 0 10 V signal Power Supply BTCS252 255 Regulator 5250 Brake 24 VDC Brake TB 90 264 VAC Ultrasonic sensor Ultrasonic sensor signal 0 10 VDC or P
36. AIN APPLICATIONS ADVANTAGE Setting type Where When Why Advantage Load cell Brake MPB 38 0 24 VDC lt lt 0 24 VDC 26 Slitter Sheeter and Coater For heavy material Limited room No fast accel decel Tension peak accepted Direct tension measure 1 Mechanically well integrated No moving part One or two load cells Memory card 0 10 VDC HMCS2000 CRD2 Controller HMCS2000 CTLC 20 Amplifier HMCS2000 DRV2 HMCS2000 WINO1 Programme Automatic setting by load cell POWER SUPPLY BTCS252 255 and HMCS2000 DRV2 see page 9 BTCS232FM RS232 SERIAL CABLE see page 23 CONTROLLER HMCS 2000 CTLC 20 Specifications Input power supply Analogue inputs Two analogue inputs Analogue outputs Two controlled channels Open loop signal Digital inputs Set point change Set point change Set point change Main features Gain multiplier Output limitation ABC binary combination ABC inputs synchronisation Stop integral form Three mounting possibilities Software password protected O Scrolling menu program O Multipurpose application RS232 communication Two ouput channels Automatic sensor scaling Programmable output configuration Output sensor information External set point change 1 Automatic or imposed PID correction 1 All features requested for tensi
37. ENSOR HMCS605 E2 see pages 20 and 21 ANALOGUE CONTROL HMCS202 E1 HMCS202 E1 Standard execution 2 HMCS202 E54 Standard IP54 protected HMCS202 EC1 Open frame execution Technical characteristics valid for 3 executions Range Values Comments Power supply 110 220 VAC selectable Open front face to access Output current capability Max 2 5 Amps short circuit protected Able to power 2 TB in parallel User settings Loop gain Front face potentiometer Offset torque Front face potentiometer Output voltage brakes 0 24 VDC Compatible all elec Warner Electric Housing Metal rugged housing Only HMCS202 E1 and E54 Loop gain 2 adjustable range selection Can be change during operation Accessories HMCS KIT1 2 3 5 and 6 See details on page 21 Sensor compatible Dancer arm with HMCS605 E2 See details on pages 20 and 21 Service manual MC403 Technical information HMC5202 control is based on classical and fixed PID terms The loop gain can be set on front face potentiometer Due to the fixed PID terms its use is limited in terms of roll diameter ratio One input is provided to change the loop gain and has to be used when diameter ratio exceeds 8 To ensure proper operation it is important to wire the function Drift Stop This function releases the Integral term as soon as the machine runs Dimensions mm G LOOP GAIN TORQUE OFFSET WARNER ELECTRIC 19 Automatic
38. IAL THICKNESS Paper note 1 TENSION FORCE BY CENTIMETER WIDTH N max N min ROLL WIDTH cm max cm min TOTAL FORCE ON ROLL WIDTH N N min MAX ROLL SPEED RPM MIN ROLL SPEED RPM THEORIC BRAKE TORQUE Nm max Nm min SLIDDING TORQUE Nm REQUIRED BRAKE TORQUE Nm max Nm min TOTAL HEAT DISSIPATION kW REQUIRED BRAKE SIZE NUMBER OF BRAKE PER ROLL REQUIRED TENSION CONTROL REGULATION Data application form START STOP t1 MACHINE STARTING TIME t2 ROLL ACCELERATING TIME t3 MACHINE DECCELARATING TIME t4 BRAKE ACCELARATING TIME MB see catalogue 1 or TB or stopping brake applied ACCELERATION TIME t2 120 F force must accelerate the roll Storage length v 120 t2 t1 if machine is accelerating faster t1 lt t2 If the dancer load is a mass the tension force will increase v 118 t1 or the dancer load is a mass the tension force will increase F 118 t2 DECCELERATION 1 Maintaining the web force warning exact values if MB or t3 defined Braking torque D v 240 t4 D 2 1 i Time 14 m D v 240 i F D 2 gt t3 necessary lenght v t4 t3 120 2 Uncontrolled emergency stop Emergency stopping time t
39. LOAD CELLS SIZING MOUNTING RECOMMENDATIONS Wrapping ngle Please keep this principle in mind the load cell installed is destined to measure the e WEB TENSION and not other constraints applied to it cy xo Take the following points into consideration before selecting sizing and installing material components Load cells location should be vibration free Vibrations will decrease quality measurement The sensing shaft fitted on or in has to be very well balanced Unbalanced shaft will create measurement oscillation causing variations in control quality 1 Adapted ball bearing have to be used to avoid original stress on load cell self aligning ball bearing Respect a reasonable sensing shaft weight web tension measure ratio Less than 1 1 Do not oversize the load cell respect to your calculation Max admitted factor 3 recommended 1 5 Respect a minimum wrapping angle on load cell Min 180 So far as it is possible use load cell in compression with web tension effect in same direction as the weight of shaft 29 Tension brakes and clutches range Brake and clutch types Series Main characteristics Torque range Electromagnetic brakes Monodisc 0 5 300 Nm 24 VDC power supply Monodisc 24 power supply Magnetic particle brakes E Completely packaged 0 04 500 Nm and enclosed unit Shaft output or bore 24 or 90 VDC power supply Magnetic parti
40. TANT CONSIDERATION ZONE 2 Typical characteristics In every machine the speed point location must be clearly identified In general one of driving nip roll is choose to set the linear speed The machine speed is considered as MASTER function The tension control whatever the selected solution works in SLAVE mode Practically the operator sets the machine 97 7 speed with simple potentiometer and all tension control system existing on the machine have to follow keeping the required tension at any speed and during all transitory speed phases Tension zone definition B C Speed point in B or C 1 Constant roll rotation speed NOTE Each zone is individually controlled Tension may be different in each zone It is Constant inertia assumed that there is no slipping on the nip roll 1 In general constant tension Y Brake system applicable System configurations OPEN LOOP CONFIGURATION Working in open loop requires an external reference setting applied to the driver The torque applied to the unwind roll has to vary according to the diameter of the roll We don t control acceleration deceleration and emergency stop as the sensor is blind regarding the band tension Application needs one sensor only which drives an amplifier without return information for the influence of correction OPEN LOOP SOLUTION Manual setting by pot Manual setting by following arm Automatic setting
41. are rated at 24 VDC nominal When selection is correct the voltage on the brake should be approxi mately 12 VDC for your maximum parameters used in calculation All TB brakes are able to work for short periods of time less than 10 seconds in the 12 24 VDC range for example in machine deceleration or in emergency stop Technical data and dimensions 170 260 TB425 Size TB260 TB500 IM TB825 IM TB1000 IM TB1225 IM 09 52 0025 500 TB1000 TB1225 TB825 OM TB1000 OM TB1225 OM TB1525 Mg min max DAVE P Continu P Alternativ 20 th Inertia Mass 4 0 08 5000 0 40 0 030 0 045 60 0 040 116 10 0 650 48 5 12 69 32 150 1 1 2400 1 224 0 360 0 650 19 6 0 152 0 041 12 105 30 5 56 5 259 36 5 Alternativ duty based on 30 minutes ON and minutes OFF 34 300 2 2000 1 076 0 520 0 950 22 3 0 290 0 095 21 138 30 5 62 316 41 5 450 3 1600 1 212 0 810 1 580 19 8 0 310 0 213 27 5 116 30 5 65 395 44 5 TB brake characteristics TB1525 IM TB825 1525 0 025 0 1 2 13 212 7 7 Steel lt 02 C Non magnetic TB170 TB1000 TB1225 TB1525 F eG 19 5 0 05 114 180 eH 15 9 175 152 5 K 10 3 76 76 L 10 75 75 5 149 3 215 9 4 90 4 90 0130 05 161 95 228 60
42. by diameter reading Automatic setting by diameter reading with additional functions Sensor L Amplifier Brake Pot 1 lt Amplifier Brake P o Amplifier Brake Pot 0 Amplifier Brake 1011 P d Ultrasonic 1 Additional functions gt Amplifier Brake Ultrasonic 1 Additional functions System configurations CLOSED LOOP CONFIGURATION Working in close loop needs one sensor This one will measure directly or indirectly the band tension Tension variations detected by sensor are sent to the brake through the control This action corrects the variation and the new corrected sen sor value is sent to the brake and so on Give a accurate tension regulation during acceleration deceleration emergency stop Sensor Amplifier Brake Position regulation by dancer arm This is an electromechanical system and the building quality for the dancer arm must be verified The band tension is created by the roll weight and or by pneumatic actuator which have sensible air exhaust Regulation by load cell This is an electromechanical system and the quality of load cells mounting must be checked The band influences directly the load cells or loads cells The load cells choice and the mounting are very important regarding over load during starting
43. cle clutches Completely packaged 0 04 500 Nm and enclosed unit Both end shaft output or bore 24 or 90 VDC power supply Permanent magnetic brakes Completely packaged and enclosed unit Shaft output Manual setting Permanent magnetic clutches 30 Completely packaged and 0 07 33 Nm enclosed unit Bore output Manual setting Tension brake sizing Two important parameters are used in brake selecting 1 Max torque requirement 1 Max thermal power to be dissipated These two values are determined by the application see calculation example on pages 78 79 ELECTROMAGNETIC BRAKE TYPE TB SELECTION TB brake selection is based on two values Max torque need Nm on the brake Max brake rotation speed for the max torque rpm As the curve given for TB selection takes the power dissipation into account this value is used Tmax torque needed at the brake for the max tension in material and the max roll diameter taking any gear ratios into account Selection point N max brake rotation speed for the max linear speed and the max roll diameter taking any gear ratios into account Note the constant tension in the web gives a constant power on the brake However we make the selection for the max torque then at full roll diameter because it s the moment where the brake has the least natural cooling Gear box 31 TB brake sel
44. ection The table pictured below left illustrates the selection of the correct TB brake The table on the right determines the maxi mum torque provided by the brake when nominal voltage is applied After selection you can consult the complete brake characteristics and dimensions on pages 34 to 35 Dynamic braking torque Maximum braking torque emergency stop TB170 TB1525 TB170 TB1525 400 500 300 400 1 525 200 300 12 100 1504 TB 10 80 60 2 100 2 80 2 40 82 2 2 60 30 5 50 40 8 20 6 50 Bs ae AR ER MN 15 10 20 8 15 1 1828 _ 6 10 4 8 3 6 5 5 2 26 1 5 3 1 0 8 2 0 6 0 4 170 1 0 2 0 6 4 10 20 60 100 200 400 0 100 200 300 400 500 15 30 50 80 150 300 500 Brake rpm 32 TB brake characteristics TB units are assembled using various parts described below Main components of the brake are armature and magnet Additional parts are offered to provide for ease of mounting TB825 1225 TB1525 TB170 TB260 TB425 TB500 Armature hub Armature Magnet 24V Termina
45. ed by places where we want to control this tension SYSTEM CONFIGURATION 1 In single roll unwinding we have one area tension between and One brake can be easy installed in The brake control system selected will be according to the accuracy required open loop or close loop ZONE 1 Typical characteristics unwind Tension zone definition Speed point B Variable roll rotation speed O Variable inertia In general constant tension X Brake system applicable SYSTEM CONFIGURATION 2 Most usual configuration with driving rolla rewinder and an unwinder 2 separate tension area with tension could be different in X and in Y Regarding accuracy required we will choice open loop or close loop In A unwinding brake in B motor for the speed and in C clutch or moto reducer for rewinding Zone 3 Typical characteristics rewind Tension zone definition B C Speed point B Variable roll rotation speed O Variable inertia Constant or Taper tension 2 Particle brake system applicable System configurations SYSTEM CONFIGURATION 3 More complicated machine with intermediary tension area between winder and unwinder The intermediary area give the line speed master slave system with speed difference in area B C give required tension All tension systems must be according the speed line in close loop IMPOR
46. eration all clutches and brakes must be mounted in horizontal axis For vertical use please consult us Magnetic particle clutches and brakes BRAKE selection 1000 W hen min roll speed and max torque are known for the BB application select the unit from theses charts t z u BB25 For continuous slip applications as tension control in an 8 N unwind or rewind application slip watts are calculated BB170 1 using the following formula BB120 1 100 Slip Watts BB65 1 0 103 max torque Nm min roll speed RPM BB35 BB12 1 10 Brakes Series B 88899888888 1000 1000 BBR500 t t 2 BBR250 4 g g BBI BBR120 1 100 100 BBR amp 1 BBR35 BBRI2 1 10 10 Brakes Series BBR 1 1 SRRSSSSSERERERSERER Speed RPM 47 Magnetic particle clutches and brakes CLUTCH selection For continuous slip applications as tension control in a rewind application slip watts are calculated using the following formula Slip Watts 0 103 max torque Nm
47. f the magnetic particle clutches and brakes make them ideal for tension control 1 load simulation cycling indexing soft starts and stops Specials are our business Special Shaft Configurations Customer specified shaft configu rations for easy machine mounting and retrofitting Wash Down Environment Stainless steel units available for extreme environments Special Torque O Maximum torque configurations to meet customer specifications Features and Benefits Torque independent of slip speed Torque is transmitted through mag netic particle chains which are formed by an electromagnetic field The torque is independent of slip speed depending only on circuit current and is infinitely variable from disengaged to rated torque Precise engagement Precision Tork magnetic particle clutches and brakes engage to transmit torque with speed and precision Response of the parti cles to the field is virtually instanta neous providing perfectly con trolled jerk free engagement Customer specified engagement Engagement time may be very gradual or extremely fast The fre quency and torque of the engage ment disengagement sequence is limited only by the capabilities of the control circuitry No wearing parts There are no friction surfaces to grab or wear and the units are not affected by changes in atmospher ic or other environmental condi tions Efficient Compact desi
48. ffering distinct advantage over competing technologies Since torque can be varied infinitely by varying the input current the magnetic particle clutches and brakes are ideal in an open loop system To close the loop in the tensioning system combine the magnetic particle clutch or brake with Warner Electric sensor and control resulting in more precise control of tension Particle clutches and the MCS2000 CTDA control provide accurate closed loop tension control for rewind applica tions Application example Information Full roll 0 5 m required Tension 22N Velocity 122 m min tension full roll Max torque 2 22 0 5 220 5 5 Nm Particle clutches and the MCS202 E1 control provide accu rate closed loop tension control for rewind applications Application example Information Core e 0 08 required Full roll e 0 23 Tension 22N Velocity 90 m mn Input speed 500 RPM Tension full roll 2 _ 22 0 23 2 torque 2 53 Speed 90 0 08 358 Velocity n D e Ip 122 0 5 78 RPM Heat pr 0 103 torque slip dissipation 0 103 5 5 78 44 46 watts Select a brake that exceeds the maximum torque and thermal energy requirements from Quick Selection Chart MPB70 Full roll Speed x D 2 90 0 23 125 RPM Slip Input speed Full roll 500 125 375
49. for information only Diameter mm MATERIAL DENSITY kg m Paper 920 Paper board 1420 Alu foil 2720 Alu wire 2750 Copper 8550 PVC 400 1050 Data application form To enable us to assist you in selecting the best product type and specification to ensure reliable and accurate tension con trol please submit this APPLICATION FORM Company Contact name Tel Fax Address City Country Date Business ROLL DIAMETER m MASS kg MIN ROLL DIAMETER m LINE SPEED m mn BRAKE RATIO i 22 21 Brake on roll axis i 1 FIRST CASE unwind tension known TENSION FORCE ON TOTAL WEB WIDTH N max N min SECOND CASE unwind tension unknown If unknown precise type of material CURRENT VALUES USED ALUMINIUM FOIL 00 7 N cm thickness micron PAPER PAPER CELLOPHANE 0 05 N cm thickness micron 10 gr m 0 5 N cm 130 gr m 3 1 N cm ACETATE 0 035 N cm thickness micron 25 gr m 0 7 N cm 150 gr m 3 8 N cm MYLAR POLYESTER 0 505 N cm thickness micron 40 gr m 1 N cm 200 gr m 5 5 N cm POLYETHYLENE 0 017 N cm thickness micron 60 gr m 1 5 N cm 250 gr m 77 N cm POLYPROPYLENE 0 017 N cm thickness micron 80 gr m 2 N cm 330 gr m 11 5 N cm POLYSTIRENE 0 06 N cm thickness micron 100 gr m 2 5 N cm 400 gr m 14 8 N cm SARAN 0 008 N cm thickness micron VINYL 0 01 N cm thickness micron VALUE PER CENTIMETER WIDTH N cm micron NUMBER OF MICRON MATER
50. gn High torque to size ratio and low consumption of electric power Versatile mounting Convenient bolt circle for easy mounting Mounting brackets available for all sizes Brakes are available with solid shafts and through bore Can be mounted horizontally or vertically to solve virtually any motion control requirement Modular Customised products Interchangeable with industry stan dard sizes Design and operation Completely packaged and enclosed unit Easy to install steel Low current gen ardware 4 erates magnetic field ae re tti Og nmi Zinc dichromate D Extremely long plating on all steel Y life spherical surfaces mr particles Magnetic powder cavity Stainless steel input shaft Convenient pilot s and mounting bolt 4 New and unique pattern j dual seal design Operating Principles Power input DC The magnetic particle unit consists of The coil is assembled inside the Sici fl four main components housing The shaft disc fits inside the Magnet iux path housing coil assembly with an air gap 1 Housing between the two the air gap is filled et particles 2 Shaft disc with fine magnetic powder 3 Coil ibd 4 Magnetic powder Engagement 7 9 When DC current is applied to the TN n M ivan at magnetic particle unit a magnetic flux m Tor
51. ing temperature must not be more than 70 C Models Resistance at 20 C Power dissipation Weight Fan tension Models Maximum torque Residual torque Voltage Current V 144 0 10 144 0 1 zl Supply cable output Magnetic particle brakes BBR65 1 0 9278 1440 10 L 157 3 5 equidistant for mounting Specifications Attention For a correct use of the brake the operating temperature must not be more than 70 C Models BBR65 1 BBV65 1 Models BBR65 1 BBV65 1 Maximum torque 65 65 Resistance at 20 C 24 24 Residual torque 0 4 0 4 Power dissipation 400 800 Voltage 24 24 Weight 98 8 8 Current Fan tension 24 VDC 115 230 BBV65 1 3 x M5 equidistant 13 122 7 2247 for mounting 1 69 C ble C ble frein ventilateur a o Lo 2 og 8 5 8 S I 4 Lr 1 Y 64 142 Magnetic particle brakes BB120 1 0 5mm old ref BB120 005 0254 0 4 x 7 equidistant 0233 0 10 1 for mounting 58 010 50 01955010 Scale 2 1 Supply cable 13 50 output M6x20
52. ls Prebored D 46 mm B5102 541 001 38 K110 0096 K5375 631 012 1100 20 Wires Indicate bore and keyway TB825 D 69 mm B5103 541 001 47 B110 0097 5365 631 016 60 2056 5103 101 002 TB1000 D 111 mm B5104 541 001 31 B110 0098 K5367 631 008 RE6 0190 6 B5103 101 002 TB1225 Taperlock bushing Armature hub Armature Drive pins Magnet IM 24V Terminals Magnet OM 24V Conduit box TB1525 Armature hub Armature Drive pins Terminals Conduit box Taperlock bushing Magnet IM 24V Magnet OM 24V D 215 mm 180 540 0394 5301 111 019 5301 101 001 R 20 Q 20 B5311 101 001 K5200 101 011 5311 631 000 30 5311 631 000 16 D 259 mm 180 540 0313 5302 111 021 5301 101 001 R 20 20 5311 101 001 5200 101 011 5312 631 000 36 D 316 mm 180 540 0015 5303 111 011 5301 101 001 4 22 20 C 5311 101 001 5200 101 011 5313 631 000 11 D 395 mm 180 540 0314 5304 111 005 04 5301 101 001 4 5314 631 000 08 2 20 O 20 C B5311 101 001 K5200 101 011 D 130 mm 180 K5300 541 004 B110 0047 K5300 101 003 5300 631 040 5311 101 001 5300 631 000 46 5200 101 010 33 TB brake characteristics All TB brakes
53. ly 24 VDC The Warner Electric switching power supply units of the BTCS252 series are designed and developed for industrial uses where safety ease of use and reliability are essential These units comply with the parameters set out by the Low Voltage Directive The low working temperature at full power operating tem perature combined with the use of first quality components ensure high reliability and duration Warner Electric switching power supply units comply with EMI standards The BTCS252 series with 90 264 VAC input has no ignition problems at full load even with low mains voltage and therefore suitable for critical supply mains This series very compact and has an IP 20 degree of protection against incidental contacts according to IEC 529 All the functions are located on the front panel and marked with IEC symbols 55 Specifications Input 90 264 VAC 110 VDC 50 60 Hz Output 24 VDC 3 A BTCS252 and 5 BTCS255 Service manual MC550 15 I Tension control in closed loop BTCS251 is a digital controller that can be used in both open or closed loop The brake driver is included and supply cur rent regulation especially for powder brakes One 3 digit display permit to follow signal variations MAIN APPLICATIONS ADVANTAGE Setting type Where When Why Advantage Dancer arm O Unwinders Output PWM included Printing machines Digital inputs Intermittent or continuous functi
54. oint change front face switch Main features Gain multiplier active low Three mounting possibilities Output limitation active low Software password protected ABC binary combination active low O Scrolling menu program ABC inputs synchronisation active low O Multipurpose application Stop integral form active low RS232 communication 1 Two ouput channels Digital outputs Automatic sensor scaling Sensor level indication Two binary outputs Programmable output configuration Output sensor information Other outputs External set point change Power supply sensor 15 VDC 100 mA 1 Automatic or imposed PID correction 5 100 mA All features requested for tension control Power supply 24 VDC Plugable memory card Voltage reference 10 VDC 10 mA Variable tension value to prevent telescopic effect on unwinding CTDA 22 Service manual MC525 HMCS2000 CRD2 MEMORY CARD All setting data saved It allows a quick loading operation on new machine or on running machine to optimise Memory for 2 different programs 1 Plugable on line in HMCS2000 ECA unit HMCS2000 WINO1 PROGRAMME The program can modify the running setting by this software running with Windows 95 98 XP 2000 IV Double tension control closed loop The command unit HMCS2000 CTLC is a complete solution with power supply and programmer display integrated There are 2 software version available See technical data below M
55. on 200 400 Voltage 24 24 Weight AT Current Fan tension 24 VDC 115 230 AC BBV12 1 3 x M5 equidistant for mounting Fan cable Brake cable 2182 055 063 h7 9115 0158 Magnetic particle brakes BB35 56 0 05 pe 48 4 01 30 i 3 x M5 equidistant o for mounting 10 5 as 8 3 S o 8 Supply cable output Y 17 H7 I Specifications Attention For a correct use of the brake the operating temperature must not be more than 70 C Models Mod les Maximum torque Resistance at 20 Residual torque Power dissipation Voltage Weight Current BBR35 60 56 0 05 3 x M5 equidistant for mounting 0 1 122 0 1 135 5 240 98 0 1 Supply cable output 61 4 0 1 Magnetic particle brakes BBV35 56 005 Supply cable output T 1 T Fan ite Ee 2 8 1 1 t t 6 x M5 equidistant for mounting 61 4 01 17 H7 67 130 4 Specifications Attention For a correct use of the brake the operat
56. on O Numeric with micro processor Adapted to powder brakes Accel machine with separated PID O Can drive motor or pneumatic brake Sensor BTCS254 Numeric control BTCS251 Brake MPB BB 38 2 Brake Power supply 35 BTCS252 255 16 Automatic setting by dancer arm BTCS251 Numeric control This device integrates a microprocessor control function and the power output to control the electromag netic powder brakes Equipped with only 3 push buttons for calibration and programming and one display with a 3 digit read ing it has been designed to be mounted on a DIN rail inside customers electrical control panel The compact size simple installation and easy to use make the instrument extremely flexible Sp cifications The 24 VDC digital inputs can be easily interfaced with the instru mentation running the machine logic PLC The type of input and output electrical signals can be chosen via a keyboard by the sys SUPPIY 24 VDC 18 tem designer and the PI D control logic results in high perfor Power with particle brake 50 W max mance precision control Power with pneumatic brake 6 W max or motor The unit has been designed specifically for machines utilising a Regulated analog output 0 10V 5 5V 4 20 mA dancer roll and magnetic particle brake however it can also be selectable via keyboard used with pneumatic brakes or mo
57. on control Plugable memory Variable tension value to prevent telescopic effect on unwinding CTLC 22 Service manual MC516 Digital outputs Sensor level indication Other outputs Power supply sensor Power supply Voltage reference HMCS2000 CRD2 MEMORY CARD All setting data saved It allows a quick loading operation on new machine or on running machine to optimise 1 Memory for 2 different programs O Plugable on line in HMCS2000 ECA unit HMCS2000 WINO1 PROGRAMME The program can modify the running setting by this software running with Windows 95 98 XP 2000 110 240 VAC selectable 0 10 VDC 10 VDG 0 20 mA 0 10 VDC active low active low front face switch active low active low active low active low active low Two binary outputs 15 VDC 100 mA 5 100 mA 24 VDC 10 VDC 10 mA 27 Load cells The FOOT MOUNTED LOAD CELL is the ideal solution to retrofit machines or for heavy tension measurement The foot mounted model has to be installed with pillow block type ball bearing supporting the sensing shaft and HFM02 are only differenciated by the physical dimensions FOOT MOUNTED TYPE and FM02 Foot mounted load cells are available in two versions With incorporated amplifier Without amplifier HFM C AC amplifier and connector on the load cell body C connector on load cell body
58. or emergency stop 26 27 Splicer system regulation Our control systems are used with double roll unwinders with splicer The 2 brakes are always controlled when one is in regulation the other has holding function through numeric control range HMCS2000 These controls include loop control with PID a lot of options and are able to be programmed by PC via RS232 line or by external programmer poc ket visual function The PID function is optimised for one inertia value The 2000 line is inclusive of an important feature namely the PID correction Based on the available diameter information you can apply continuous PID correction When no information is available an internal PID change can be programmed A PID relative values ode Each parameter P I and D can be set individually for the smallest core and biggest diameter soon as the correct parameters are found for the extreme diameter value they are stored The diameter information provided will fix the PID values for the present diameter value This will allow the system to keep an excellent stability during the whole diameter evolution In the case where the diameter infor mation is not available we can provide this signal by installing SE sonic sensor or by working with internal correction The external 5 diameter information supplied to the controller will ensure better precision compensation compared
59. ot 10 K Ohm 0 10 V signal 0 2A lt 115 230 t Brake MPE BB Regulator 250 14 Automatic setting by diameter reading Ultrasonic sensors Dimensions see page 11 Model HSCUA 130 HSCUA 140 Power supply 15 to 30 VDC max 30 mA 15 to 30 VDC max 30 mA Min distance 100 mm 400 mm Max distance 900 mm 2400 mm N 2 N Accuracy 1 mm 1 mm Protection class IP67 IP67 HSCUA 130 HSCUA 140 Accessory 5 m cable 5 cable Service manual MC487 MC488 BTCS 250 Current regulator power supply for particle brakes The 250 card was designed especially for controling particle brakes and for increasing their yield In fact this permits complete elimination of residual magnetism in the powder and therefore it is possible to work in low torque ranges without limits The components used are professional type and this assures absolute reliability over time Its limited size facilitates wall mounting Connection is easy and is done via 10 pole connector fastened to the terminals with screws Specifications Power supply BTCS250 C 28 VAC or 24 VDC Power supply BTCS250 T 110 230 VAC 50 60 Hz Input 0 10 VCC from Pot 10K Output 0 2 A modulated PWM BTCS250 C Only card BTCS250 T Card with transformer Service manual MC544 Dimensions mm 171 120 108 120 BTCS250 C BTCS250 T BTCS 252 255 Single phase power supp
60. que current curve chain is formed linking the RI shaft disc to the housing As the cur ioo rent is increased the magnetic flux ETTER 5 becomes stronger increasing the 2 3 torque The magnetic flux creates 3 extremely smooth torque and virtually eo no stick slip o 40 Disengagement A 20 When DC current is removed the 0 magnetic powder is free to move within the cavity allowing the input shaft to rotate freely 0 20 40 60 80 100 120 Percent of rated current Magnetic particle clutches and brakes Selection Sizing To properly size magnetic particle clutches or brakes the thermal energy slip watts and torque transmitted must be consi dered If thermal energy and torque are known for the application select the unit from the charts to the right Speed Velocity m min V RPM 1 9 coil m In rewind applications the motor RPM should be higher 1096 than the fastest spool RPM In applications with the web running over a pulley or in a nip roll application use the pulley diameter as the roll diameter kk Thermal Energy slip watts 1 When a brake or clutch is slipping heat is generated Heat is described in terms of energy rate and is a function of speed inertia and cycle rate For continuous slip applications such as tension control in an unwind or rewind application slip watts are calculated using the following formula Slip Wa
61. running machine to optimise Memory for 2 different programs 1 Plugable on line in HMCS2000 ECA unit HMCS2000 WINO1 PROGRAMME The program can modify the running setting by this software running with Windows 95 98 XP 2000 23 Ill Double tension control closed loop compact The command unit HMCS2000 CTDA is complete solution with power supply and programmer display integrated There are 2 software version available See technical data below MAIN APPLICATIONS ADVANTAGE Setting type Where When Why Advantage Dancer arm Printing machines Absorb tension peak Intermittent function O Can act as store Flying splice need Easy flying splice Accel machine phase well absorbed Flexibility Sensor HMCS605 E2 Memory card HMCS2000 CRD2 Amplifier HMCS2000 DRV2 Controller HMCS2000 CTDA 20 0 10 VDC HMCS2000 WINO1 programme 24 Automatic setting by dancer arm POWER SUPPLY BTCS252 255 and HMCS2000 DRV2 see page 9 ROTARY SENSOR HMCS605 E2 see pages 20 and 21 BTCS232FM RS232 SERIAL CABLE see page 23 CONTROLLER HMCS2000 CTDA20 Specifications Input power supply 110 240 selectable Analogue inputs Two analogue inputs 0 10 VDC Analogue outputs Two controlled channels 10 VDC 0 20 mA Open loop signal 0 10 VDC Digital inputs Set point change active low Set point change active low Set p
62. setting by dancer arm ROTARY SENSOR HMCS605 E2 position sensor is used 2 possible ways To detect dancer moving in the closed loop installation working on dancer principle To sense the diameter of the roll to operate open loop control or make PID compensation in closed loop installation HMCS605 E2 is ideal for easy mounting It is encapsulated in rugged metal housing preventing mechanical shocks Furthermore it is provided with built in switch in order to change the signal output polarity Sensor 5605 2 Power supply 10 to 30 VDC 30 mA or 5 to 15 Max detection angle 200 or 100 Sensitivity 25mV V Service manual MC483 TB brake Dimensions mm Mounting min 47 max 70 20 Automatic setting by dancer arm HMCS605 E2 MOUNTING KIT The HMCS202 Exx is designed to work with dancer arm principle Usually the sensor is a rotary type Warner Electric sensor HMCS605 E2 are delivered without mounting kit Mounting kit comprises of CABLE WITH CONNECTOR S COUPLING MOUNTING BRACKETS and all necessary SCREWS Various KITS have various lengths of cable and cable with or without connector at control end side HMCS2000 line requires free leads HMCS2000 control line is provided with terminal block HMCS202 Exx requires a connector HMCS202 Exx is provided with
63. sion velocity 60 Constant tension 26 30 60 13 watts provided by Film tensioning hysteresis unit Constant tensioning supplied by hysteresis unit Select MB5 Model Overload protection Torque limiting Soft start Information required Power motor 0 37 kw Speed motor 1750 RPM Motor horsepower method Stub Shaft Adapter Conveyor How to size Torque 9550 9550 0 37 1750 2 Nm Clutch Coupling Motor Select an MC5 Model from the Torque limiting Hysteresis clutch provides specification chart overload protection Material handling Hysteresis clutch can provide overload protection and soft start Tension selection The WARNER ELECTRIC experience enables us to offer a tension guide as shown below For any special material not included in the chart below please consult WARNER ELECTRIC These values are usual values for information only please check exact tension you need in your application PAPER WEIGHT F f x width cm Tension f N cm 20 40 60 80 100 120 140 Weight PW g m2 FOIL F f x width cm 5 2 c 8 7 0 2 0 4 0 6 0 8 1 1 2 Thickness Tension f A o 2 5 3 3 Usual values
64. stment Torque is set with a large knurled adjust ment ring Infinite adjustability between minimum and maximum settings This allows units to be fine tuned to your unique require ment Torque is constant with respect to speed By using the Precision Tork unit you can solve almost any torque control problem O Torque is extremely consistent smooth at low as well as high speeds No external control or power source Simple to install O Nothing to monitor Unaffected by power interruption or power fluctuation Safe to use Dependable performance 1 Smallest possible transition from static to dynamic torque O Virtually eliminates the stick slip pheno menon associated with friction devices Long life The only wearing parts are the ball bearings Extremely accurate Precision Tork units out perform all other devices at low RPM Versatile mounting Easy to retrofit Clutches are available with hollow bores for mounting on motor shafts or jack shafts Bolt circles allow for fixed mounting adding a pulley or stub shaft adapters Brakes are available with solid shaft outputs Rotating centre disc Multiple pole high Low drag seals energy magnets Dichromate xs 4 Precision ball coating for bearings There improved corrosion mechanical M EN Hollow shaft 27 resistance N wear parts
65. tic particle clutches BC500 34 18 Supply cable 16 0 10 LT output 18 00 14 1 V o S A lt e Oo ID ot 2 6 FO S v 8 e 8 x 8 5 equidistant for mounting 55 7 120 0 Specifications Attention the operating temperature must not be more than 70 C VIEW A Brushes holder Models BCR500 Maximum torque 500 1 33 Residual torque Voltage Current R sistance at 20 Power dissipation at 500 RPM Power dissipation at 1000 RPM zl Weight BCR500 28 40 10 14 Supply cable output T 1 9 _ 2 o S 6 es 2 H S S 8 35 g Ol S 1 1 8 x 8 5 mm 91 equidistant for mounting 110 120 0 1 Magnetic clutches and brakes Precision Tork units provide constant torque independent of slip speed They offer excellent overload and jam protec tion for all drive train components and also provide soft starts with zero slip when a preset torque is reached Precision Tork permanent magnet clutches and brakes do not require maintenance and provide extremely long life Features and Benefits Fast precise torque adju
66. tors on unwind or rewind Analog output 0 10V applications and with amplified load cells PWM output 24VDC 1 8 A max Analog input keyboard selection 0 5V 0 10V 0 20 mA Digital input 24 VDC Working temp 0 50 C Weight 180g Standard approval CE UL Mounting Rail DIN Service manual MC553 Applications Dimensions Torque control with DANCER ROLL Mode 01 73 71 26 5 a 5 25 x ni 17 I Simple tension control closed loop If your machine requires a very accurate web tension control then you need to work in closed loop An important unit in the loop is the sensor Several possibilities are offered The choice now depends on the kind of machine you are building the mechanical construction and the max tension value you desire to control MAIN APPLICATIONS ADVANTAGE Setting type Where When Why Advantage Dancer arm 18 1 Printing machines Intermittent function Flying splice need 1 Absorb tension peak O Can act as store Easy flying splice Accel machine phase well absorbed 1 Flexibility Sensor HMCS605 E2 110 230 VAC Analogue Control HMCS202 E1 L FAD Corre WARNER Additional functions Brake open 1 Emergency stop O Drift stop stop integral term of PID 1 Gain change Automatic setting by dancer arm ROTARY S
67. tts 0 103 torque Nm speed RPM 2 For cycling applications heat is generated intermittently and is calculated using the following formula speed RPM 10000 Slip Watts 0 00077 J kgm The average heat input must be below the clutch or brake s heat dissipation rating If the application generates intermittent heat dissipation use the average speed for the thermal energy slip watts calculations Torque 1 Tension applications calculate torque as a function of roll radius and tension T N D 2 C Nm 2 Soft controlled stopping applications calculate torque as a function of inertia speed and desired time to stop the load J kgm RPM 9 55 Time C Nm Magnetic particle clutches and brakes Quick Selection Charts MPB2 MPC2 1800 Heat dissipation 1500 10 watts max 5 1200 oa a 900 600 300 0 0 04 0 09 0 13 0 18 0 02 0 07 0 11 0 15 0 2 Torque Nm 0 22 MPB70 MPC70 1090 Heat dissipation 800 100 watts max 2 600 2 400 200 0 1 13 2 26 3 39 4 51 5 64 6 77 79 Torque Nm MPB15 MPC15 1000 Heat dissipation 800 20 watts max
68. vantage Diameter reading The most commonly used Physical reading no reset solution in open loop Easy to start up No operator intervention admitted Large roll e ratio Power supply BTCS252 255 Ultrasonic sensor 27 90 264 gt gt Y gt 4 Brake 0 24 VDC 0 10VDC lt Ome Brake MPB BB Amplifier HMCS2000 DRV2 or 1 0 10 VDC 1 K Numeric control BTCS251 10 Automatic setting by diameter reading ULTRASONIC SENSORS Model HSCUA 130 HSCUA 140 Power supply 15 to 30 VDC max 30 mA 15 to 30 VDC max 30 mA Min distance 100 mm 400 mm Max distance 900 mm 2400 mm N 2 Accuracy 1 mm 1 Protection class IP67 IP67 HSCUA 130 HSCUA 140 Accessory 5 m cable 5 cable Service manual MC487 MC488 Dimmensions mm amp 8 C 10 5 4 6 5 20 e tt 8 g E uu i Miox1 Hal 18 5 M12x1 81 EE 40 M30x1 5 24 HSCUA 130 HSCUA 140 BTCS 252 255 Single phase power supply 24 VDC Dimensions mm The Warner Electric switching power supply units of the BTCS252 series are designed and developed for industrial uses where safety ease of use and reliability are essential These units comply with
69. www warnerelectric eu com Warner Electric AMERICA U S A WARNER ELECTRIC Gardner Street 449 South Beloit Illinois 61080 U S A Tel 01 815 389 3771 Fax 01 815 389 2582 OCEANIA AUSTRALIA WARNER ELECTRIC AUSTRALIA Unit 1 11 Packard Avenue Castle Hill N S W 2154 Tel 612 9894 0133 Fax 612 9894 0368 DISTRIBUTION Most products are available through authorised local distributors please contact your nearest WARNER office for information Distributors are located in the following countries Argentina Greece Portugal Austria Holland Scotland Belgium India Slovakia Brazil Ireland Slovenia Croatia Israel South Africa Bosnia Italy Spain Czech Rep Lithuania Sweden Egypt New Zealand Switzerland Finland Norway Turkey France Poland U S A MC507r gb 0607 2007

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