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Tension Controller HI-3300

1. 4 Remote I O RIO Interface to the Allen Bradley Network5 PROFIBUS 5 5 EtherNet IP Pending 5 Modbus Over TCP IP 5 ControlNet 5 Chapter 2 Calibration 7 About Chapter 2 7 Getting Started 7 Binding 7 Traditional Calibration From the Front Panel 7 About Traditional Calibration 7 Mechanical Calibration Setup for Traditional Calibration 7 Traditional Calibration From the Web Page 10 Soft Calibration from the Front Panel 11 About Soft Calibration 11 Soft Calibration from the Web Page 13 Force Factor lt es B mue EB osoa dos lt ES 14 Electrical Check Procedures 14 C2 Calibration From the Front Panel 15 C2 Calibration From the Web Page 16 Chapter 3 Operating Procedures 19 About Chapter 3 0 0 19 Getting Started 19 HI 3300 Tension Controller Service Manual Help 4 s
2. 22 About the Prod 1 Parameter 22 Prod 2 Parameter 23 About the Prod 2 Parameter 23 Prod 3 Parameter 23 About the Prod 3 Parameter 23 Setting the P Proportional Integral D Derivative Parameters PID from the Front Panel 24 About PID Rum vom moo eR 24 AutoGain Parameter 24 About the AutoGain Parameter 24 Taper Percent Parameter Rewind Only 25 About The Taper Percent Parameter 25 Checking the Device Data List 25 Monitoring the HI 3300 from the Web 26 Software Downloads for Your 3300 27 Table of Illustrations Chapter 1 Chapter 2 Overview FIG 1 1 Table of Illustrations UNWIND ZONE 2 FIG 1 2 REWIND ZONE 2 FIG 1 3 MID PROCESS ZONE 2 Calibration 7 FIG 2 1 CALIBRATION MECHANICAL SETUP 7 FIG 2 2 SETUP MENU SELECTING CALIBRATION 7 FIG 2 3 CALIBRATION SELECTING SENSOR TYPE 8 FIG 2 4 TRADITIONAL CALIBRATION ZERO VALUE 8 FIG 2 5 CAL
3. 27 FIG 3 25 3300 SERIES DOWNLOAD LINK 27 FIG 3 26 3300 SERIES DOWNLOAD PAGE 27 1 CHAPTER 1 Overview CHAPTER 1 OVERVIEW General Introduction to the Hardy Tension Controller HI 3300 Service Manual This Service Manual provides the Technician with a com plete description of installation setup calibration mapping and troubleshooting procedures for the HI 3300 Tension Controller To get the maximum service life from this prod uct technicians should use this instrument in accordance with recommended practices either implied or expressed in this manual Before using the Tension Controller all service personnel should read and understand all cautions warnings and safety procedures referenced or explicitly stated in this manual to insure the safe operation and repair of this instru ment Hardy Instruments sincerely appreciates your busi ness We encourage input about the performance and operation of our products from our customers Should you not understand any information in this manual or experience any problems with this product please contact our Technical Support Department at Phone 858 278 2900 FAX 858 278 6700 E Mail e hardysupportG hardyinst com e hi salesQ hardyinstruments com Or visit our web site at http www hardyinstruments com Our web site is full of useful information about our tension control process weighing and vibration analysis products You ca
4. Romam Rus A AO 19 About Flelps s s cem 220 as e o memes 19 Operating the Tension Controller from the Front Panel 19 Front Panel Display 19 Button Functions 19 Start Button 19 Stop Button lt pss Sema eR 19 Help Button 19 Auto M Button 19 Left Right Buttons 20 Enter BUTON 20 ExIt BUllOn cem I m veto eL 20 Clear Button oom m om 20 Gain 1 Button 20 2 ABC Button 20 Setup 3 DEF Button 20 Taper 4 GH sss 20 SKE Buttons gt sete Bo ee S 20 6 MNO Button 20 Calibrate 7 PQRS Button 20 8 TUV Button 20 Test 9 WXYZ Button 21 User Q Button 21 0 Char Button 21 Starting Up for the First Time 21 Selecting Product from the Front Panel 22 Setpoint in Use Parameter 22 About the Setpoint in Use Parameter 22 Prod 1 Parameter
5. INSTRUMENTS Tension Controller HI 3300 User s Guide Tension Controller i Table of Contents Table of Contents Table of Contents i Table of Illustrations Chapter 1 Overview 1 General Introduction to the Hardy Tension Controller HI 3300 Service Manual 1 Description ix tere Stare Se Sie lp 1 Typical Applications 2 Hardy Web Tech 3 Connectivity mentum Rum ROS a mum AUS 3 Setup Dialogs 42200 ii ta 3 Mappedil O 2 mme Remo 3 WAVERSAVERO a le 3 C29 Calibration 3 On Board Diagnostics 3 Secure Memory Module SMM 4 BHelaySs s xe RR eee ROS RE 4 Analog Output 4 Options 500225 fuese E E moe Re UR ep oe chee NE 4 LOGE docebit Du SI x Nh fy ies tn 4 HI3000 RC 4 PB 4 4 4 4 MB 4 Communication Options 4 DeviceNet
6. A tension control process is a dynamic system which is changing all the time The actual tension changes from moment to moment Most often the actual tension will be greater or less than the setpoint The HI 3300 Tension Con troller produces a correction signal that is sent to the tension ing mechanisms clutch motor etc in order to maintain the Setpoint Tension Proportional More appropriately called gain which is a multiplier that increases the error signal to a value which is useful as a correction signal The correction signal is propor tional to the original error and either increases or decreases the tension to correct for the error signal from the load sen sor Integral More appropriately called stability provides a correction to the PID algorithm that smooths or slows the Controller output so that tensioning mechanisms don t over react which adds stability to the system Derivative More appropriately called response looks for the rate at which the error rate changes The derivative accounts for and adjusts the output signal that corresponds to the rate of change D is different from P in that D responds early to a rate of change and P only reacts to the absolute error signal at any given point in time NOTE All entered values are for illustration purposes only Your requirements will vary Step 1 Press the Gain 1 button The PID Parameters Dis play appears with the cursor in front of Propor
7. Step 13 Click in the Capacity text field See Fig 2 16 Type in the combined Maximum capacity of the load cells on your system Step 14 Click on the Do Cal High button Step 15 A page telling you that the Do Cal High Calibration completed OK See Fig 2 18 Cal completed OK Back FIG 2 18 CAL COMPLETED OK Step 16 Click on Home to return to the Tension Control ler Home page Step 17 Traditional calibration is complete Soft Calibration from the Front Panel About Soft Calibration Soft Calibration does not require you disassemble your web Zone or process to do another hard calibration By entering a few calibration parameters you used during Traditional Cali bration you can do a Soft Calibration which resets the Ten sion Controller to the original Traditional Calibration This eliminates the necessity of using the Test Weights over and over again Simply enter the calibration values and do the Soft Cal and you are back in calibration Step 1 In the Calibration Menu press the button until the cursor is in front of Soft Cal See Fig 2 19 0 00 Cal ibr ation Tr ad Cal gt Soft Cal Snsr Type FIG 2 19 CALIBRATION MENU SELECTING SOFT CALIBRATION Step 2 Press the Enter button The Soft Cal Sub Menu appears with the cursor in front of Ref Wgt See Fig 2 20 0 00 SOFTCAL Do Soft Cal gt Ref Wi Capacity FIG 2 20 SOFT CALIBRATION MENU ENTERING REFERENCE
8. e Auto Instrument controlling the process e Manual Operator controlling the process e Stop Controller and Process are stopped You must press Start to Start or Restart the Controller 0 00 HI Web Standby 25 Out put Set point 5 0016 FIG 3 3 FRONT PANEL OPERATING MODE DISPLAY STANDBY 0 00 Manual HI Web Output 2596 Set point 5 0016 FIG 3 4 FRONT PANEL OPERATING MODE DISPLAY MANUAL 0 00 HI Web Auto Output 2596 Set point 5 0016 FIG 3 5 FRONT PANEL OPERATING MODE DISPLAY AUTO 0 00 HI Web Stop 25 Out put Set point 5 0016 FIG 3 6 FRONT PANEL OPERATING MODE DISPLAY STOP Let s stop and look at the information on the Operating Dis play e large number at the top of the display is the current tension in pounds force lbf as measured by the load sensor e The HI Web is the Instrument ID e Standby Auto Manual or Stop is the current operational mode of the instru ment e Output is the percentage of the full Analog output signal e Setpoint is the Tension Setpoint value entered for the current product NOTE Setpoint displays lb however it is measuring pounds force Ibf Selecting Product from the Front Panel Step 1 Press the Product button The Product Menu appears See Fig 3 7 NOTE Changes made are not saved in non volatile memory Once you disconnect power to the instrument all these settings are dele
9. 0650 0140 01 Ver sion 2 4 000F Serial 1234 FIG 3 19 TEST DATA DISPLAY PART NUMBER PROGRAM VERSION Step 5 These are read only displays The information is important e PP Program Part Number This is the part number of the firmware To order additional copies of the firmware you will need this number This is also additional information available to a service techni cian for troubleshooting e Often a technician needs to know the pro gram version to determine if the correct version is being used A Hardy Technical Support Technician will ask what version of software you are currently using to determine the source of a problem You can find the version here Step 6 Press the Exit button to return to the Test and Data Menu Step 7 Press the Exit button to return to the operating dis play HI 3300 Tension Controller 26 User Guide Monitoring the HI 3300 from the Web Page To monitor the HI 3300 remotely via your Web Browser you simply enter the IP address of the HI 3300 you want to mon itor It is just that simple If the Tension Controller is con nected to the Internet you can monitor the instrument from any where in the world from your Web browser or WAP browser enabled Cellular Phone Step 1 In your browser address field enter the IP address of the HI 3300 you want to monitor See Fig 3 20 We used the IP address of our demo Tension Con troller that is available to all users Step 2 You can als
10. CONFIGURATION 13 FIG 2 29 CONFIGURATION MENU SELECTING CALIBRATION 14 FIG 2 80 CALIBRATION PAGE SOFT CALIBRATION 14 FIG 2 31 SOFT CAL SUCCESSFUL 14 FIG 2 32 PROPERLY INSTALLED LOAD CELL WITH NO BINDING 14 FIG 2 33 CONFIGURATION MENU SELECTING SETUP 15 FIG 2 34 CALIBRATION SELECTING SENSOR TYPE 15 FIG 2 35 TRADITIONAL CALIBRATION ZERO VALUE 15 FIG 2 36 CALIBRATION 15 FIG 2 37 C2 CALIBRATION SUB MENU 15 FIG 2 38 ENTERING THE REFERENCE POINT 16 FIG 2 39 C2 CAL ENTERING WRAP ANGLE 1 16 FIG 2 40 C2 CAL ENTERING FORCE FACTOR 16 FIG 2 41 C2 CALIBRATION 16 FIG 2 42 CONFIGURATION MENU SELECTING SETUP 17 FIG 2 43 CONFIGURATION PAGE 17 FIG 2 44 CALIBRATION SUB MENU VIEW 1 17 Chapter 3 HI 3300 Tension Controller Service Manual FIG 2 45 CALIBRATION 50 2 17 FIG 2 46 METHOD 1 C2 CALIBRATION 17 FIG 2 47 CAL COMPLETED 18 Operating Procedures 19 FIG 3 1 FRONT PANEL 19 FIG 3 2 DIRECTIONAL BUTTONS 20 FIG 3 3 FRONT PANEL OPERATING DISPLAY STANDBY 21
11. FIG 2 3 CALIBRATION SELECTING SENSOR TYPE Step 5 Press the Right or Left arrow buttons to select the sensor type The sensor types are categorized by the sensitivity of the Load Cell type which is posted on the load cell or with the load cell documentation See Fig 2 3 Press the Enter Button to set the entry Press the button until the cursor is in front of Capacity See Fig 2 4 0 00 0 3 V 200106 Step 6 Step 7 Setup Snsr Type gt Capacity C2 Cal FIG 2 4 TRADITIONAL CALIBRATION ZERO VALUE Step 8 Use the alphanumeric key pad and enter the total capacity of all the load sensors used for your appli cation For example if you are using two load sen sors that are rated at 100 Ibs each you enter 200 Ibs 100 x 2 Maximum Capacity Step 9 Press the Enter button to set the entry Step 10 Press the Enter Button to set the entry Press the button until the cursor is in front of C2Cal See Fig 2 5 3300 Tension Controller 8 User s Guide 0 00 Capacit y 200105 gt C Cal gt Trad Cal Cal ibr ation FIG 2 5 CALIBRATION C2 CAL Step 11 Press the button until the cursor is in front of Trad Cal See Fig 2 6 0 00 Cal ibr ation C2 Cal gt Trad Cal Soft Cal FIG 2 6 CALIBRATION SELECTING TRADITIONAL CALIBRATION Step 12 Press the Enter button The Trad Cal menu appears with the cursor pointing to Ref Wgt
12. I 5 JKL Button Enters the integer 5 and the letters J K L 6 MNO Button Enters the integer 6 and the letters M N O Calibrate 7 PQRS Button Enables the user to calibrate C2 Traditional Cal Soft Cal the instrument when in the operating display Also enters the integer 7 and letters P Q R S 8 TUV Button Enters the integer 8 and the letters T U V 21 CHAPTER 3 Operating Procedures Test 9 WXYZ Button Enables you to enter the selftest or diagnostics mode Also enters the inter 9 and letters W X Y Z User 9 Button Enables you to change the 3 digit user code while in the standby mode Also enters the period underscore _ and symbols O Char Button Enters the integer 0 in the display When you push the button the second time a set of characters appears in the display Step 1 Using the and buttons move the cursor in front of the character you want to display Step 2 Press the Enter Button to select the character Step 3 Press the Exit Button to return to the display The character should now appear next to the cursor Starting Up for the First Time When the HI 3300 Tension Controller powers up after deliv ery from the factory The Operating Mode Display appears in the Front Panel Display with the controller on Standby See Fig 3 3 The Operating Display always indicates one of the following modes of operation See Figs 3 4 5 6 e Standby Prepared and Waiting to Start
13. See Fig 2 7 0 001b T ad Cal Do Cal Span gt Ref Do Cal Low FIG 2 7 CALIBRATION ENTERING REFERENCE WEIGHT Step 13 Traditional Calibration requires a zero point and the physical placement of test weights on the scale To Set the Reference Weight Remove all weight from the end of the cable or cord See Fig 2 8 The Refer ence weight should almost always be 0 00 e Use the alphanumeric key pad and enter 0 00 9 CHAPTER 2 Calibration e Press the Enter button to set the entry Step 14 Press the button until the cursor is in front of Do Cal Low See Fig 2 9 Process Wrap Angles wd Idler Roll Idler Roll Transducer Roll No Weight FIG 2 8 CALIBRATION SETUP WITH NO WEIGHT 0 00 0 001b T ad Cal Ref Wt gt Do Cal Low gt Span 10 00 1b FIG 2 9 DO TRADITIONAL CALIBRATION ZERO Step 15 Press the Enter button to do the Cal Low Zero Calibration e If Function OK appears the Zero Cali bration is complete e ERR appears go to Chapter 7 Troubleshooting for more information Step 16 Press the button until the cursor is in front of Span Wet See Fig 2 10 To Set the Span Value 0 00 10 0016 T ad Cal Do Cal Low gt Span Wt Do Cal Span FIG 2 10 TRADITIONAL CALIBRATION ENTERING SPAN WEIGHT Place the certified test weight on the end of the cable or cord See Fig 2 11 e Use the alphanumeric
14. The Name and tension set point of the Product is displayed on the Operational Display Prod 1 is also the default setpoint parameter if you do not configure Prod 2 or Prod 3 Step Press the button until the cursor is in front of Prod 1 See Fig 3 8 PARAMETER PROD1 RANGE NAME 9 CHARACTERS SETPOINT 0 99999 DEFAULT NONE 0 00 Prod 1 Pr oduct Set pnt In Use gt Prod1 Prod 2 FIG 3 8 PROCESS SETUP MENU SETTING PROD 1 PARAMETERS Step 2 Press the Enter button The Prodi Menu appears See Fig 3 9 0 12 Ib Pol yeth Pr od1 gt Setpoint Pr odNane FIG 3 9 PROD1 MENU SETTING PRODUCT 1 NAME Step 3 The cursor is now in front of Setpoint Step 4 Use the alphanumeric key pad to enter the tension setpoint you want for this product We use 0 12 Ib which is a typical running tension for Polyethylene Yours may vary Step 5 Press the Enter button to set the entry Step 6 Use the alphanumeric key pad to type the Product Name In our example we used Polyeth for Poly thylene In order for the entire Product Name to 23 CHAPTER 3 Operating Procedures appear on the Operational Display try to use an abbreviation of the product name Press the Enter button to set the entry Press the Exit button to return to the Instrument Setup Menu Press the button until the cursor is in front of Prod2 See Fig 3 10 Step 7 Step 8 Step 9 Prod 2 Parameter About
15. a long thin flexible structure Common web materials include paper film foil non wovens and textiles The angle between the ingoing and outgoing tangent of a web on a roller or equiva lently the angle the web deflects as it goes over a roller High wrap angles help ensure web roller traction HI 3300 Series 4 Operation and Installation Index Index Symbols Left Right Buttons 20 Button 9 Numerics 0 Char Button 21 10 100 BaseT Ethernet 1 2 ABC Button 20 2S 4 3rd Party 3 4 6 MNO Button 20 8 TUV Button 20 A About Help 19 About PID 24 About Soft Calibration 11 About the AutoGain Parameter 24 About the Prod 1 Parameter 22 About the Prod 2 Parameter 23 About the Prod 3 Parameter 23 About the Setpoint in Use Parameter 22 About The Taper Percent Parameter 25 About Traditional Calibration 7 AC 4 Aggressive 24 Allen Bradley Remote l O 1 3 4 Alphanumeric character LCD 19 Alphanumeric Entry 20 Alphanumeric Value 20 Analog 1 Analog Output 4 Analog Output Option 4 Application Specific Web Tension Process Weighing And Condition Monitoring Instruments 1 Auto 21 Auto M Button 19 AutoGain Parameter 24 B Back 11 Backspace Function 20 Binding 7 Block Transfer Commands 5 Booster Power Supply 4 Brakes 1 Built In Diagnostics 2 Built In Smart Diagnostics Knowledgebase 2 Button Functions 19 C C2 CAL Sub Menu 15 C2 Cal Type 15 C2 Calibration Completed OK 18 C2
16. blocking The user friendly keypad and display provide a short learning curve for plant operators and menu security levels allow better control over process setpoints The Tension Controller also provides Quick Calibration capabilities which allows the user to calibrate the web or strand process control without the use of test weights thus saving on time effort and cost The Electronic Diagnotics within the controller allows the user to troubleshoot issues related to installation sensor peformance or system noise all through the keypad or a PC on the same network as the controller Downloads for current HI 3300 tension controller users FIG 3 25 DOWNLOAD LINK Step 2 Select the link Downloads for current HI 3300 weight controller users HI 3000 Series Controllers Downloads Click on any ofthe links below to download the software you need for your HI 3000 Series Controller Hardy Auto Update Lets you update HI 3000 Series firmware IP Setup Lets you setthe IP address of your HI 3000 Series unit HI 3010 Filler Dispenser Firmware Latest firmware Version 2 12 00 HI 3030 Weight Controller Firmware Latest firmware Version 2 13 00 00 HI 3600 Machine Monitor Firmware Latest firmware Version 2 6 02 HI 3300 Tension Controller Firmware Latestfirmware Version 2 7 01 0000 Master Firmware Latest firmware Version 2 4 DeviceNet EDS ControlNet EDS OPC Float DPD OPC Mi
17. in the Sensitivity text field Enter the sensitivity of the load sensors you are using for this application Click in the Wrap Angle 1 text field Enter Wrap Angle 1 Click in the Wrap Angle 2 text field Step 8 Enter Wrap Angle 2 Step 9 Click in the Capacity text field Step 10 Enter the Total Load Cell capacity Step 11 Click in the Ref Wet text field Step 12 Enter the Reference Weight 0 00 Step 13 Click on the Do Soft Cal Step 14 If the Soft Calibration was successful a message page appears with Cal completed OK See Fig 2 31 Step 15 Soft Calibration Complete Step 5 Step 6 Step 7 HI 3300 Tension Controller 14 User s Guide Cal completed OK Back FIG 2 31 SOFT CAL SUCCESSFUL Force Factor CAUTION BINDING ON A ROLL OR LOAD SENSOR DOES NOT ALLOW THE LOAD SENSOR FREE MOVEMENT AND MAY PREVENT THE INSTRUMENT FROM RETURNING TO THE ORIGINAL ZERO REFERENCE POINT Step 16 Check to see that the load cell is mounted so that 100 of the load vertically passes through the load cell See Fig 2 32 Direction of the applied load Vessel LT Ja mmm MEE UO Km 5 O oes es NES N y CN gt A gt v d 5 4 N m _ A FIG 2 32 PROPERLY INSTALLED LOAD CELL WITH NO BINDING Electrical Check Procedures Step 1 Check to see that there is power to the c
18. key pad to enter the value of the test weight If a 10 Ib weight is used enter 10 Process Wrap Angle hy Idler Roll Idler Roll Transducer Roll Known Weight FIG 2 11 SPAN CALIBRATION SPAN WEIGHT Step 17 Press the button until the cursor is in front of the Do Span Cal See Fig 2 12 0 00 10 0016 T ad Cal Span Wht gt Do Cal Span gt Ref Wjt 0 00 FIG 2 12 TRADITIONAL CALIBRATION SPAN CALIBRATION Step 18 Press the Enter button to do the Span Calibration HI 3300 Tension Controller 10 User s Guide If Function OK appears the Span Cali bration is complete fan ERR number appears go to Chapter Configuration 7 Troubleshooting for more information Process Setup Step 19 End of Traditional Calibration Step 20 Remove the rope and weight from the rollers or Instrument Setup sheaves Traditional Calibration From the Web Page e Control Link Step l On the Tension Controller Home Page click on Configuration See Fig 2 13 The Configura tion page appears See Fig 2 14 Mapping FIG 2 14 CONFIGURATION PAGE SELECTING CALIBRATION Step 2 Click on Calibration The Calibration Sub menu appears See Figs 2 15 amp 16 Configuration Calibration Instrument ID HI Web FIG 2 13 CONFIGURATION MENU SELECTING SETUP Load Sensor Number 2 Ref wgt 0 Ib Wrap Angle 1 Wrap Angle 2 60 4 Method 2 Calibration Z
19. or control multiple applications from one display and allows 3rd party I O to be easily added to any system You no longer have to hard wire each device to an I O module or I O block The network also provides access to the intelligence present in the instruments for supe rior diagnostics and troubleshooting to help increase system up time The DeviceNet network lets you monitor your plant floor devices from a central location and reconfigure them as your needs change or service them as required The DeviceNet network s capabilities help reduce integration and reduce installation and wiring costs 5 CHAPTER 1 Overview Remote l O RIO Interface to the Allen Bradley Net work The RIO port allows bi directional communications with Allen Bradley Programmable Logic Controllers PLC and Small Logic Controllers SLC The HI 3300 represents a selectable 1 4 1 2 3 4 or full rack of discrete I O 32 bits in the Logic Controllers output and input image files to the PLC Controller and supports both discrete and block trans fers of data It can support up to 230 4 Kbaud transfer rates PROFIBUS Allows bi directional communications to Profibus Process Fieldbus products including those made by Siemens GE Fanuc and Texas Instruments This interface supports PROFIBUS DP Decentralized Periphery and processes both Selectable Predetermined and Block transfer com mands It supports up to 12 Mbaud transfer rates OPC OLE for Process Contr
20. sensitivity of measurement or control A law that states that stresses equal the product of a material constant call modulus or Young s modulus and strains A roller which is driven by the web rather than by an electric motor belt or other exter nal means An independent tension zone typically created between two driven nip points on a converting line Also referred to as a Mid Process Zone An electronic sensor that measures force On converting machinery load cells under the ends of an undriven roller are often used to measure web tension A cylinder upon which a roll is wound Abbreviation for Machine Direction which is the direction of material flow through a machine NIP PID CONTROL PLI RATIO REWIND ZONE ROLL ROLLER SAMPLE AND HOLD SOFT START STRAIN GAUGE SUBSTRATE TENSION TRANSDUCER TENSION LIMIT SWITCH TLS TAPER TENSION TENSION ZONE HI 3300 Series 2 Operation and Installation Two parallel rolls pressed together on converting machinery between which the web passes An abbreviation for Proportional Integral and Derivative control A common three function algorithm found in closed loop controllers for automatically matching the con trol output to a set value of interest Most tension controllers on the market that use a tension measurement input form transducers or load cells use PID for tension control DFE uses the terms Gain Stability and Response to describe each co
21. the Prod 2 Parameter This parameter menu allows the user to give the Process a name and set the tension setpoint The Name and tension set point of the Product is displayed on the Operational Display PARAMETER PROD2 RANGE NAME 9 CHARACTERS SETPOINT 0 99999 DEFAULT NONE Pr oduct Pr od 1 gt Prod2 Prod FIG 3 10 PROCESS SETUP MENU SETTING PROD 2 PARAMETERS Step 1 Press the Enter button The Prod1 Menu appears See Fig 3 11 0 1516 Pr od2 gt Setpoint Pr odNane FIG 3 11 PROD2 MENU SETTING PRODUCT 2 NAME amp SETPOINT Step 2 The cursor is now in front of Setpoint Step 3 Use the alphanumeric key pad to enter the tension setpoint you want for this product We used 0 15 Ib which is a typical running tension for Saran Yours may vary Step 4 Press the Enter button to set the entry Step 5 Use the alphanumeric key pad to type the Product Name In our example we used Saran Polyvi nylidene Chloride In order for the Product Name to appear on the Operational Display try to use an abbreviation of the product name Press the Enter button to set the entry Press the Exit button to return to the Instrument Setup Menu Press the button until the cursor is in front of Prod3 See Fig 3 12 Step 6 Step 7 Step 8 Prod 3 Parameter About the Prod 3 Parameter This parameter menu allows the user to give the Process a name and set the tension setpo
22. up to eight load sensors a junc tion box interconnect cable and an instrument with C2 capa bilities such as the Tension Controller All Hardy Instruments C2 certified load sensors contain digital infor mation detailing its unique performance characteristics The Hardy Tension Controller reads the performance characteris tics of each individual load sensor and detects the quantity of load sensors in the system Calibration is performed by sim ply adding a reference point from the front panel PDA or via the Web Server The reference can be zero no weight on the scale or alternatively a known weight on the scale The instrument is capable of performing traditional calibration such as with the use of certified test weights NOTE WAVERSAVER and C29 are registered trade marks of Hardy Instruments Inc On Board Diagnostics The HI 3300 has a built in diagnostics utility which enables the operator to rapidly troubleshoot a tension zone from the front panel of the controller or via the Web Server Simply press the Test button and scroll through several tests that will furnish the current state of each of the parameters that con cern your application and the web tension system Help is just a click away in the event you should not understand the information on the display or need a description of the parameter Secure Memory Module SMM The Secure Memory Module stores critical configuration up to three product setpoints ca
23. 2 PID Control for Rewinding Zone 2 PID Control for Unwinding Zone 2 PID Parameters Display 24 PLC 1 Polyethylene 22 Polystyrene 24 Index Pounds Force Ibf 21 PP Program Part Number 26 Process Configuration 22 Prod 1 22 Prod 1 Parameter 22 Prod 2 22 Prod 2 Parameter 23 Prod 3 22 Prod 3 Parameter 23 Profibus 1 5 Profibus Process Fieldbus 5 Profibus Interface 4 Program Version 26 Programmable Logic Controllers PLC 5 Proportional 24 Provide Feedback Link 3 R Read Only Display 26 Read Only Field 17 Ref Wgt 8 16 Reference Weight 17 Reference Weight Text Field 17 Relays 4 Remote I O 5 Right Arrow Button 20 Right or Left Arrow Buttons 8 RIO 4 Roller 12 Rope and Weight 10 RS Networks 3 S Saran 23 Secure Memory Module SMM 4 Security Violation 16 Selectable Predetermined 5 Sensitivity 12 Serial Number 26 Set the Span Value 9 Setpoint in Use Parameter 22 Setpoints Entered 19 Setting the P Proportional Integral D Deriva tive Parameters PID from the Front Panel 24 Setup Menu 7 15 Setup Wizards 3 Setup 3 Button 15 Setup 3 DEF Button 20 Sheave 12 Siemens 5 Small Logic Controllers SLC 5 Smart Devices 4 SMM 4 SMM Secure Memory Module 1 Snsr Type 8 15 Soft Calibration 11 Soft Calibration from the Front Panel 11 Soft Calibration from the Web Page 13 Span Calibration 9 Span Weight Field 11 Span Wgt 9 Stand Alone PID Closed Loop Controller 1
24. Calibration From the Front Panel 15 C2 Calibration From the Web Page 16 C2 Weighing System 3 C29 Calibration 3 C29 Electronic Calibration 1 C29 Second Generation Calibration 3 C2Cal 8 Cal Completed OK 11 16 Cal Low Zero Calibration 9 Calibrate 7 PQRS Button 20 Calibration 7 Calibration Menu 7 8 15 Calibration Page 11 Calibration Performed 19 Calibration Procedures 7 Calibration Sub Menu 10 17 Calibration 7 Button 7 Capacity 8 12 Cellular Phone 26 Certified Test Weight 9 11 Checking the Device Data List 25 Clear Button 20 CN 4 Communication Cables 19 Communication Options 4 Configuration 10 Configuration Page 10 Connectivity 3 ControlNet 5 Core Technologies 7 Corrective Action 16 Cursor 7 D DCS 1 Derivative 24 Device Data List 25 DeviceNet 4 19 DeviceNet Interface 3 Do C2 Calibration 16 Do C2 Calibration Button 18 Do Cal High Button 11 Do Cal Low Button 11 Do Cal Low Calibration 11 Do Cal Low 9 Do Soft Cal 13 Do Trad Cal 9 Drive 7 Dual Scale Input 4 E Embedded Web Server 3 Enter Button 20 ERR 10 Ethernet Industrial Protocol 5 Ethernet IP Port 3 EtherNet IP Pending 5 Exit Button 20 Exit button 19 Extranet 1 F Fanuc 5 Force Factor 13 Front Panel 19 Front Panel Display 19 Function Error 16 Function OK 9 G Gain 1 Button 20 GE 5 Getting Started 7 19 H Hard Cal 7 Hardy C2 Second Generation 7 Hardy Instruments C2 Certified Load Sensors 3 Hard
25. FIG 3 4 FRONT PANEL OPERATING MODE DISPLAY MANUAL 21 FIG 3 5 FRONT PANEL OPERATING MODE DISPLAY AUTO 21 FIG 3 6 FRONT PANEL OPERATING MODE DISPLAY STOP 21 FIG 3 7 INSTRUMENT SETUP MENU SELECTING PRODUCT 22 FIG 3 8 PROCESS SETUP MENU SETTING PROD 1 PARAMETERS 99 Sus Sas 22 FIG 3 9 PROD1 MENU SETTING PRODUCT 1 NAME 22 FIG 3 10 PROCESS SETUP MENU SETTING PROD 2 PARAMETERS 23 FIG 3 11 PROD2 MENU SETTING PRODUCT 2 NAME amp SETPOINT 23 FIG 3 12 INSTRUMENT SETUP MENU SETTING PROD 3 PARAMETERS 23 FIG 3 13 PROD3 MENU SETTING PRODUCT NAME 23 FIG 3 14 PID PARAMETERS SETTING PROPORTIONAL 24 FIG 3 15 PROCESS SETUP SETTING AUTOGAIN 25 FIG 3 16 PROCESS SETUP MENU SETTING THE TAPER PERCENT 25 FIG 3 17 TEST AND DATA MENU SELECTING DEVICE DATALIST 25 FIG 3 18 TEST DATA DISPLAY INSTRUMENT ID MODEL NUMBER SN 26 FIG 3 19 TEST DATA DISPLAY PART NUMBER PROGRAM VERSION 26 FIG 3 20 BROWSER ADDRESS FIELD ENTERING IP ADDRESS 26 FIG 3 21 BROWSER ADDRESS FIELD ENTERING HI3300 HARDYINST COM 26 FIG 3 22 3300 HOME PAGE SELECTING OPERATION 26 FIG 3 23 OPERATION SELECTING MONITOR 27 FIG 3 24 MONITORING THE HI 3300
26. I 3300 Tension Controller 4 Service Manual AC AC input power for the HI 3000 Series remote mount instru ment to act as a booster power supply for multiple instru ments on Devicenet RIO Allen Bradley Remote I O interface allows full instrument capabilities to be communicated remotely to and from an Allen Bradley processor CN ControlNet Enables multiple controllers to control I O on the same wire and permits multicast of both inputs and peer to peer data reducing traffic on the wire and increasing sys tem performance Swivel Mount including bracket and mounting hardware This mount enables the user to mount the instrument outside an enclosure and rotate the HI 3300 for easier viewing Communication Options NOTE For installation and configuration instructions for all the Communication Options please see the HI 3000 Installation and Operation Manual on this CD DeviceNet DeviceNet is a low level network designed to connect the Hardy HI 3000 Series Instruments to higher level controllers such as PCs PLCs or embedded controllers The DeviceNet Network is an open global industry standard communica tion network designed to provide an interface through a sin gle cable from a programmable controller or PC directly to all HI 3000 Series instruments as well as smart devices such as sensors push buttons motor starters simple operator interfaces drives and other weigh modules With DeviceNet the user can monitor
27. IBRATION C2 CAL 8 FIG 2 6 CALIBRATION SELECTING TRADITIONAL CALIBRATION 8 FIG 2 7 CALIBRATION ENTERING REFERENCE WEIGHT 8 FIG 2 8 CALIBRATION SETUP WITH NO WEIGHT 9 FIG 2 9 DO TRADITIONAL CALIBRATION ZERO 9 FIG 2 10 TRADITIONAL CALIBRATION ENTERING SPAN WEIGHT 9 FIG 2 11 SPAN CALIBRATION SPAN WEIGHT 9 FIG 2 12 TRADITIONAL CALIBRATION SPAN CALIBRATION 9 FIG 2 13 CONFIGURATION MENU SELECTING SETUP 10 FIG 2 14 CONFIGURATION PAGE SELECTING CALIBRATION 10 FIG 2 15 CALIBRATION SUB MENU 10 FIG 2 16 METHOD 2 CALIBRATION ZERO CAL 11 FIG 2 17 CAL LOW COMPLETED OK 11 FIG 2 18 CAL COMPLETED OK 11 FIG 2 19 CALIBRATION MENU SELECTING SOFT CALIBRATION 11 FIG 2 20 SOFT CALIBRATION MENU ENTERING REFERENCE WEIGHT 12 FIG 2 21 SOFT CALIBRATION MENU ENTERING LOAD SENSOR CAPACITY 12 FIG 2 22 SOFT CALIBRATION MENU ENTERING SENSITIVITY OF THE LOAD CELLS 12 FIG 2 23 TEST WEIGHT CONFIGURATION 12 FIG 2 24 SOFT CALIBRATION MENU ENTERING WRAP ANGLE 1 13 FIG 2 25 SOFT CALIBRATION MENU ENTERING WRAP ANGLE 2 13 FIG 2 26 SOFT CALIBRATION ENTERING FORCE FACTOR 13 FIG 2 27 SOFT CALIBRATION DOING THE SOFT CALIBRATION 13 FIG 2 28 HOME PAGE SELECTING
28. P Combining a versatile scaleable and ubiquitous physical network Ethernet with a universal networking standard TCP IP and a vendor neutral data representation MOD BUS gives a truly open accessible network for exchange of process data It is also extremely simple to implement for any device that supports TCP IP sockets Simplicity MODBUS TCP IP simply takes the MOD BUS instruction set and wraps TCP IP around it If you already have a MODBUS driver and if you understand Ethernet and TCP IP sockets you can in short period of time have a driver up and running and talking to a PC ControlNet ControlNet enables multiple controllers to control I O on the same wire and permits multicast of both inputs and peer to peer data reducing traffic on the wire and increasing system performance HI 3300 Tension Controller 6 Service Manual 7 CHAPTER 2 Calibration CHAPTER 2 CALIBRATION About Chapter 2 Chapter 2 pertains to the calibration procedures for the HI 3300 Tension Controller Alternatives to any procedures implied or explicitly contained in this chapter are not recom mended In order for the Tension Controller to work prop erly it must be calibrated prior to operation Be sure to follow all the procedures completely to insure that the weights read by the Tension Controller are accurate It is very important that the user and service personnel be famil iar with the procedures contained in this chapter befor
29. Standby 21 Start Button 19 Starting Up for the First Time 21 Stop 21 Stop Button 19 Support Section 1 Swivel Mounted 1 System Gain PID 20 T Taper Percent Parameter Rewind Only 25 Taper 4 GHI 20 Technical Support Department 1 Tension Controller 1 7 19 Tension Controller Home Page 10 Tension Setpoint 22 Test and Data Menu 25 Test button 3 Test Weight 9 Test 9 WXYZ Button 21 Texas Instruments 5 The Secure Memory Module 4 Trad Cal 8 Traditional Calibration 8 15 Traditional Calibration 3 7 Traditional Calibration From the Front Panel 7 Traditional Calibration From the Web Page 10 U Units 5 JKL Button 20 User _ Button 21 Vendor Neutral Data Representation 5 Vertically Passes 14 VPN 1 W WAP Enabled Devices 3 WAP Browser 26 WAVERSAVER 3 WAVERSAVER 3 WAVERSAVER Technology 3 Web and Strand Tension Control 2 Web Browser 19 Wireless Connectivity 1 Wrap Angle 1 12 Wrap Angle 1 Text Field 17 Wrap Angle 2 13 Wrap Angle 2 Text Field 18 HI 3300 Tension Controller User Guide Z Zero Cal Reference Weight 11 Zero Point 8 INSTRUMENT 9440 Carroll Park Drive Suite 150 San Diego CA 92121 Telephone 1 800 821 5831 FAX 858 278 6700 Web Address http www hardyinstruments com Hard Instruments Document Number 0596 0286 01 Rev B Copyright December 2004 Dynamic Instruments All Rights Reserved Printed in the U S A
30. Step 3 Push the Exit button to return to the current menu Operating the Tension Controller from the Front Panel lt Tension Controller INSTRUMENTS _ OK ALERT DANGER o Setup 5 NU QT N ee Auto m Product EA 7 AAA AAA FIG 3 1 FRONT PANEL Front Panel Display The Front Panel Display has a large tension value display with 4 line x 20 Alphanumeric character LCD The screen displays all the menus for Configuring Calibrating and Operating the HI 3300 Tension Controller Button Functions Start Button The Start Button starts or restarts the tension process Start could also be a dual start where the Start Button will start the process in the controller and send a signal to the VFD to start Stop Button The Stop button stops or initiates a shutdown sequence for the controller The Stop could also provide a signal to a remote station as well Help Button The Help button displays a Help message for the current Menu item the Menu item in front of the cursor that is dis played In Standby the Help button does not display a Help message Auto M Button Enables you to enter or exit the Manual or Auto mode of operation You also see Auto or Manual in the upper right hand corner of the display telling you which mode you are currently in When in the Auto mode the PID control is targeting the tension setpoint L
31. W 2 Step 3 Step 4 Method 1 C2 Calibration Load Sensor Number 2 Ref wat 0 00 Ib Wrap Angle Wrap Angle 2 FIG 2 46 METHOD 1 C2 CALIBRATION The Load Sensor number is a read only field It tells you how many load sensors are connected to the instrument If this number does not reflect the actual number of load sensors go to Chapter 7 Troubleshooting Double click in the Weight text field to enter the Reference Weight or click in the Reference Weight text field See Fig 2 44 Type in the ref erence weight which should in almost all cases be 0 00 Step5 Double click in the Wrap Angle 1 text field NOTE Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 If you do not know the wrap angle and know the Force Factor enter the Force Factor instead See Fig 2 45 Enter the Wrap Angle 1 value Double click in the Wrap Angle 2 text field Enter the Wrap Angle 2 value Click on the Do C2 Calibration button A page appears telling you that the C2 Calibration completed OK See Fig 2 47 Cal completed OK Back FIG 2 47 CAL COMPLETED OK Click on Back to return to the Calibration page Click on Home to return to the Tension Control ler Home page C2 calibration is complete HI 3300 Tension Controller User s Guide 18 19 CHAPTER 3 Operating Procedures CHAPTER 3 OPERATING PROCEDURES About Chapter 3 Chapter 3 c
32. WEIGHT Step 3 Use the alphanumeric key pad and enter 0 00 if the current setting is not 0 00 Step 4 Press the Enter button to set the entry Step 5 Press on the button until the cursor is in front of Capacity See Fig 2 21 0 00 Ref Wjt 0 00 gt Capacity 20010 Sensit ivit y 268 SOFT CAL FIG 2 21 SOFT CALIBRATION MENU ENTERING LOAD SENSOR CAPACITY Step 6 Use the alphanumeric key pad and enter the com bined Maximum capacity of the load cells on your system Step 7 Press the Enter button to set the entry Step 8 Press on the button until the cursor is in front of Sensitivity See Fig 2 22 0 00 20010 SOFT CAL Capacity gt Sensitivity 268 30 0 W ap Angl e 1 FIG 2 22 SOFT CALIBRATION MENU ENTERING SENSITIVITY OF THE LOAD CELLS Step 9 Use the alphanumeric key pad and enter the Sensi tivity of the load cells on your system HI 3300 Tension Controller 12 User s Guide Step 10 If you do not know the sensitivity of your load cell do the following With no tension on the roller record the millivolt reading using either a digital multimeter or the Diagnostics function located in the Test Menu See Chapter 7 Diagnostics for instructions e Apply a known test weight to the roller or sheave See Fig 2 23 Load Cell FIG 2 23 TEST WEIGHT CONFIGURATION e Record the millivolt reading X3 Formula Sensitivity X2 X1 Test Weight Sensiti
33. core when the process is complete PARAMETER TAPER PERCENT RANGE 0 100 DEFAULT 046 0 00 Taper gt Taper Per cent FIG 3 16 PROCESS SETUP MENU SETTING THE TAPER PERCENT Step 1 Use the alphanumeric key pad and enter the Taper Percent value you want for this application Step 2 Press the Enter button to set the entry Step 3 Press the Exit button to return to the operating dis play Checking the Device Data List The Device Data List includes the ID Serial Number Model Number Hardy Part Number Firmware Version of the instrument Should you need to contact Hardy Technical Support you may need this information Step 1 From the Operating Display press the Test 9 button The Test and Data Menu appears with the cursor in front of Device Data List See Fig 3 17 0 00 TESTAND DATA MENU gt Device Data List Diagnostics FIG 3 17 TEST AND DATA MENU SELECTING DEVICE DATA LIST Step 2 Press the Enter button The Device Data List Dis play appears with the cursor in front of Instrument ID See Fig 3 18 0 00 Data List Serial 1234 gt ID Web Model HI 3300 FIG 3 18 TEST DATA DISPLAY INSTRUMENT ID MODEL NUMBER S N Step 3 In this menu you can view the Instrument ID Model Number and Serial Number of the instru ment This is a read only display Step 4 Press the down arrow button until the next three parameters appears See Fig 3 19 0 00 Data List gt
34. e installing or operating the HI 3300 Tension Controller Getting Started The HI 3300 Tension Controller can be calibrated three ways The first is the Hardy C29 Second Generation calibra tion which requires no test weights Hardy C2 Calibration is one of the Core Technologies The second calibration tech nique is called traditional calibration which requires certified test weights It is important to note that the procedures con tained in this section either explicitly stated or implied should be followed to guarantee the performance of the instrument The third is Soft Calibration which does not require any test weights Alternatives to the procedures listed here are not recommended Before you can calibrate the instrument you first need to check to see if the system is ready to be calibrated Binding Due a visual check to see if the load sensors have been installed so that nothing is binding the load cell or other parts of the web tension system Make sure that nothing is draped over the rolls or sheaves such as a cable electrical cord or other objects You want to be sure that you are able to zero or tare the instrument to compensate for the tare weight dead load Step 1 Step 2 Make sure that all cables are properly connected between the load sensors junction boxes drive and the Tension Controller Step 3 That the cord and weight are installed correctly and that the known weight is suspended freely with nothi
35. eft Right Buttons FIG 3 2 DIRECTIONAL BUTTONS The and buttons allows the operator to adjust the run ning tension up or down when in Auto Mode and when in operational display The and buttons enables the operator to adjust the output up or down when in Manual Mode When in a Sub Menu the and buttons move the cur sor vertically allowing the user to scroll through each item of a menu The Left Right arrow buttons move the cursor hori zontally left and right The Left arrow button has an added backspace function For example if there are Alphanumeric characters that appear in the display as you press the left button it erases the characters The Right arrow button moves the cursor to the right in the display and does not erase an alphanumeric entry Enter Button The Enter button enters the Alphanumeric value entered for a menu item in the display The Enter button also enters the selections from a pick list Exit Button The Exit button disregards the current value entry restores the previous value and moves the cursor to the previous menu Clear Button The Clear button clears the total Alpha Numeric Entry and repositions the cursor for the first entry Gain 1 Button Enables you to change the System Gain PID while in the Operating Mode Also enters the integer 1 in the display NOTE The Gain correlates to the MaxTension Setting which is part of the PID algorithm HI 3300 Tensi
36. er 7 Troubleshooting of this manual for corrective action e Another message may occur which is Secu rity Violation This means that the User does not have the security level required to do a calibration Step 24 Press the Exit button until you return to the Standby display Step 25 C2 calibration is complete C2 Calibration From the Web Page Step On the Tension Controller Home Page Click on Configuration See Fig 2 42 The Configura tion page appears See Fig 2 43 17 CHAPTER2 Calibration Tension Control Home Page FIG 2 42 CONFIGURATION MENU SELECTING SETUP Configuration Process Setup Instrument Setup C tion Control Link Mapping FIG 2 43 CONFIGURATION PAGE Step 2 Click on Calibration The Calibration Sub menu appears See Figs 2 44 45 amp 46 Configuration Calibration Instrument ID Web Method 1 C2 Calibration Load Sensor Number 2 Ref wet 0 Ib Wrap Angle 1 60 4 Wrap Angle 2 poa Do 2 Method 2 Calibration Zero Cal Refwgt 0 16 Do Cal Low Method 2 Calibration Span Span Wet 10 16 Sensitivity 0 2462 Capacity 200 lb Do Cal Higt FIG 2 44 CALIBRATION SUB MENU VIEW 1 Set Force Factor Tension times FORCE FACTOR equals force on load cell Setting its value here will calculate angles suitable for use in calibrations above Force factor o1 736 FIG 2 45 CALIBRATION SUB MENU VIE
37. ero Cal Ref wet om Method 2 Calibration Span Span Wet 10 16 Sensitivity 0 2462 Capacity 200 lb Do Cal High Di FIG 2 15 CALIBRATION SUB MENU 11 CHAPTER 2 Calibration Method 2 Calibration Zero Cal Refwgt 0 Ib Do Cal Low Method 2 Calibration Span Span Wet 10 10 Sensitivity 0 2462 Capacity 200 1h Do Cal High FIG 2 16 METHOD 2 CALIBRATION ZERO CAL Step 3 If the Method 2 Calibration Zero Cal reference weight is any value other than 0 0 go to Step 4 otherwise go to Step 10 Step 4 To clear the entry press the left mouse button and hold while moving the cursor over the current Reference Weight which highlights the weight value Step 5 Use your keyboard to type in 0 00 See Fig 2 16 Step 6 Click on the Do Cal Low button Step 7 A page telling you that the Cal Completed OK appears See Fig 2 17 Cal completed OK Back FIG 2 17 CAL LOW COMPLETED OK Step 8 Click on Back to return to the Calibration page Step 9 Placea certified test weight on the rope or cord this is your span weight Step 10 To enter the Span Weight double click in the Span Weight field See Fig 2 16 Step 11 Use your keyboard to type in the new Span Weight value In our example we entered 10 00 Ibs See Fig 2 16 Step 12 Click in the Sensitivity text field Use your key board and enter the rated sensitivity of the Load Sensor
38. h Tension e Misalignment e Control Lost The HI 3300 Tension Controller is field configurable for all web tension applications including but not limited to con verting printing plastic film textiles and other industries where web tension is required This instrument is a stand alone PID closed loop controller which operates in auto or manual modes for web tension process control The display keeps the user up to date as to the current tension value out put in percentage operating status and tension setpoint for the selected product Output alarms warn the operator of High tension Low tension Misalignment etc The Tension Controller contains Hardy Instrument s core features e WAVERSAVER Eliminates the effects of vibration on the scale e C28 Electronic Calibration Calibration without test weights e SMM Secure Memory Module Mem ory for manual transfer of configuration data to another HI 3300 instrument s All of Hardy s 3000 Series instrumentation is loaded with standard features like a selectable 10 100 BaseT Ethernet port and an embedded web server to link performance diag nostics and setup data to and from your local Intranet Extra net VPN or via the Internet World Wide Web An IR Infra Red port provides wireless connectivity to PDA devices for easy configuration loading and transfer of data Optional Devicenet ControNet Profibus Allen Bradley Remote 109 Ethernet and Ethernet Com
39. he symbol Abbreviation for Cross machine Direction sometimes also abbreviated as XMD which is the direction perpendicular to the material flow and material plane in a machine In many plants this is referred to as TDE or Transverse Direction The thickness of a web usually expressed in micrometers or mils thousandths of an inch A disc brake pad or baking mechanism involving opposing brake pads that grip a rotating disc The process of a web material from one form to another Converting processes include calendaring coating die cutting embossing laminating printing punching sheeting slitting treating winding and unwinding A hollow tube often of fiber plastic or metal upon which a roll is wound A mandrel upon which rolls are wound A moving roller sensor used for feedback control of web tension Output from a sensor which is input to a controller for maintaining a control setpoint A control technique to improve responsiveness of controls by letting the actuator know a change is need even before its sensor detects it A thin polymer plastic web such as found in stretch wrap or garbage bags Also a thin liquid A force resisting motion Friction between webs and rolls is important because it deter mines whether the web will track or lose traction Friction between web and web is important because it determines how stable a stack or wound roll will be Friction on machines is important because it may compromise the
40. ing Soon Modbus Analog and OPC interfaces allow multiple applications to be viewed and controlled from one display and allows 3rd party to be easily added to the system Mapped I O saves you wiring costs by distributing the I O where you need it at the process or in the control room The controllers act as Mas ter over Ethernet IP and Devicenet communications while optional interfaces for Allen Bradley Remote I O Profibus and Analog provide communications to PLC and DCS Sys tems HI 3300 Tension Controller Service Manual NOTE registered trademarks are the property of their respective trade associations and corpora tions Built in diagnostics provide the ability to troubleshoot indi vidual load cells Alarms alert you to problems or potential problems that can affect your process The Tension Control ler has Help dialogs that walk you through the instrument set up while Web Site help files are just a key press away Typical Applications 2 aM e PID Control for Unwinding Zone e PID Control for Mid Process intermedi ate Zone e PID Control for Rewinding Zone e Web and Strand Tension Control NAK FIG 1 1 UNWIND ZONE FIG 1 3 MID PROCESS ZONE 2 3 CHAPTER 1 Overview Hardy Web Tech We have implemented Hardy Web Tech our new Online Tech Support Knowledge Base to serve your tech support needs better than ever before Hardy Web Tech helps you immediately find answers
41. int The Name and tension set point of the Product is displayed on the Operational Display PARAMETER PROD3 RANGE NAME 9 CHARACTERS SETPOINT 0 99999 DEFAULT NONE Pr ocess Setup Prod2 gt Prod3 Start Level FIG 3 12 INSTRUMENT SETUP MENU SETTING PROD 3 PARAMETERS Step 1 Press the Enter button The Prod3 Menu appears See Fig 3 13 Pr od3 1001b Pol ysty gt Setpoint Pr odNane FIG 3 13 PROD3 MENU SETTING PRODUCT 3 NAME Step 2 The cursor is now in front of Setpoint Step 3 Use the alphanumeric key pad to enter the tension setpoint you want for this product We use 1 00 Ib which is a typical running tension for Polystyrene Yours may vary Step 4 Press the Enter button to set the entry Step 5 Use the alphanumeric key pad to type the Product Name In our example we used Polysty for Poly styrene In order for the Product Name to appear on the Operational Display try to use an abbreviation of the product name Step 6 Press the Enter button to set the entry Step 7 Press the Exit button to return to the Operating Dis play Setting the P Proportional Integral D Derivative Parameters PID from the Front Panel NOTE Changes made are not saved in non volatile memory Once you disconnect power to the instrument all these settings are deleted You must use the Instrument or Process Configuration in Setup to save parameters to non volatile memory About PID
42. is in front of Do Soft Cal See Fig 2 27 0 00 0 1736 SOFT CAL For ce Fact or gt Do Soft Cal Ref Wot 0 00 FIG 2 27 SOFT CALIBRATION DOING THE SOFT CALIBRATION Step 22 Press the Enter button to do the Span Calibration e If Cal Completed OK appears the Soft Calibration is complete e fan ERR number appears go to Chapter 7 Troubleshooting for more information Step 23 End of Soft Calibration Step 24 Press the Exit button to return to the Operating Menu Soft Calibration from the Web Page Step 1 From the Home Page Click on Configuration See Fig 2 28 The Configuration Page appears See Fig 2 29 2 uf ue 3 ai d in 16 wp Bees Fi O f eo MALA 0 onore E FIG 2 28 HOME PAGE SELECTING CONFIGURATION Configuration Process Setup Instrument Setup C tion Control Link Mapping Security FIG 2 29 CONFIGURATION MENU SELECTING CALIBRATION Step 2 Click on Calibration The Calibration page appears Scroll down to Method 3 Calibration Soft Cal See Fig 2 30 Method 3 Calibration Soft Cal Sensitivity 2 0000 Wrap Angle 1 80 0 Wrap Angle 2 90 0 Capacity 200 Ib Ref wgt 0 00 Ib Wrap angles are computed during a SPAN calibration provided that the correct Sensitivity and Capacity were entered Do Soft Cal FIG 2 30 CALIBRATION PAGE SOFT CALIBRATION Step 3 Step 4 Click
43. le if you are using two load sen sors that are rated at 100 Ibs each you enter 200 Ibs 100 x 2 2 Maximum Capacity Step 7 Press the Enter button to set the entry Press the button until the cursor is in front o C2 Cal See 0 00 Cal ibr ation Capacit y gt C Cal Tr ad Cal FIG 2 36 CALIBRATION Step 8 Press the Enter button The C2 CAL Sub menu appears with the cursor in front of Load Sensor Numb See Fig 2 37 C2 CAL Do C2 Cal gt Load Sensor Num 2 Ref wgt 0 001b FIG 2 37 C2 CALIBRATION SUB MENU Step 9 The Load Sensor number is a read only field It tells you how many load sensors are connected to the instrument Step 10 Press the down arrow button to move the cursor in front of the Ref Wet See Fig 2 38 0 00 Load Sensor Num 2 gt Ref wgt 0 0010 W ap Angl e 1 60 0 C2 CAL FIG 2 38 ENTERING THE REFERENCE POINT Step 11 Step 12 The Reference Weight should be 0 00 if it is not use the alphanumeric keypad and enter 0 00 lb Press the arrow button to move the cursor in front of Wrap Angle 1 See Fig 2 39 0 00 C2 CAL Ref wgt 0 001b gt Wap Anglet 60 0 W ap Angl e2 60 0 FIG 2 39 C2 CAL ENTERING WRAP ANGLE 1 Step 13 Step 14 Step 15 Step 16 Step 17 Step 18 NOTE Use the alphanumeric key pad and enter Wrap Angle 1 Press the Enter button to set the entry Press the button to move the cursor i
44. libration and setup data of the HI 3300 Tension Controller thereby protecting this informa tion from corruption During system operation when a new parameter is entered the SMM automatically updates the value in its memory Data stored in one HI 3300 can be restored in another HI 3300 by physically transferring the SMM to the new instrument The SMM is conveniently accessible from the instruments rear panel Relays The HI 3300 is fitted with four 4 standard internal select able 24 240 VAC or 5 60VDC Solid State electronic SPST relays The relays can be used to open or close valves or gates turn on off motor mixers vibration equip ment heaters or coolers to name a few Analog Output The Analog Output Option enables the transmission as 0 5 VDC 0 10 VDC 0 20 mA or 4 20 mA or the reverse of these and makes it possible to span these ranges over a por tion of the weight data Two analog option boards can be installed in each instrument both voltage and current data are available simultaneously Options 2S Dual Scale Input Adds another channel to the standard instrument enabling the user to add another load cell HI 3000 RC Rear cap for the HI 3000 Series controllers Upgrades the entire assembly to a NEMA 4X rating by enclosing all the rear panel connectors PB Profibus interface allows instrument capabilities to be com municated remotely to and from a Siemens or other Profibus compatible processor H
45. lier For example e stored Gain is 20 and the Gain multi plier is 0 5 and the Output Level is 80 the Adjusted Gain Level therefore is Adjusted Gain Level 20 80 x 0 5 Adjusted Gain Level 20 40 Adjusted Gain Level 60 25 CHAPTER 3 Operating Procedures e Inourexample the Gain rate of change of control is three times greater at an 80 output level than at a 096 output level PARAMETER AUTOGAIN RANGE 0 000 2 000 DEFAULT 0 000 0 00 PID Par arret er s Der ivative 0 0 gt AutoCain 25 Pr opor tional 30 FIG 3 15 PROCESS SETUP SETTING AUTOGAIN Step 1 Use the alphanumeric key pad and enter the Auto Gain value you want for this application To shut off the AutoGain enter zero 0 00 Step 2 Press the Enter button to set the entry Step 3 Press the until the cursor is in front of Taper See Fig 3 16 Taper Percent Parameter Rewind Only NOTE Changes made when using the taper button are not saved in non volatile memory Only the taper value entered in Setup are saved Once you dis connect power to the instrument all these settings are deleted You must use the Instrument or Pro cess Configuration in Setup to save parameters to non volatile memory About The Taper Percent Parameter The Taper Percent is determined by the percentage differ ence between the diameter of a full roll or the diameter of the roll when starting a process and the diameter of the
46. mponent of PID control because they are more descriptive of each An abbreviation for Pounds per Lineal Inch A unit of tension measurement expressed as the total force in pounds on the web in the machine direction MD divided by the width in inches of the web Expressing tension in PLI allows comparison of typical tensions between various width webs or various web substrates An output feature on a tension controller that multiplies for unwind applications or divides for rewind applications the sampled control output by a factor adjustable between 1 and 10 The feature allows an instantaneous change i control output to cor respond to the roll diameter change that takes place during a flying splice A tension zone typically on converting machinery created between a driven nip roll or other tensioning point and the driven core onto which the web is wound A web in wound roll form This term is also used in the converting industry for rollers A rotating cylinder used for web transport Aliases include idler rolls idler rollers drums rolls pipe rollers A control feature that locks the tension controller output at whatever level it is at when an external contact closes The lock is maintained until the contact opens Used in fly ing splice applications to prevent instability during the splice Also actuated by the Ration function A tension controller feature used in unwinds zones soft start causes the controller output to dr
47. n also get the latest updates of the Tension Controller Manual The latest revised manuals are available FREE in the Support Section of our Web Site While you re on the site feel free to visit the other web pages which can provide answers to your questions about load sensors brakes vibra tion analysis or other Hardy instruments Be sure to sign up for the Hardy Newsletter to get the latest information on all Hardy products and services For answers to technical issues and service problems check the Hardy Web Tech on our Hardy Web Site Most problems can be resolved by the Hardy Web Tech 365 days a year 24 hours a day 7 daysa week You can still contact a technician by phone during our operating hours if necessary Description The Hardy Instruments Tension Controller is part of a com plete line of application specific web tension process weigh ing and condition monitoring instruments The Tension Controller is available as a model HI 3300 a stand alone closed loop load cell based PID controller with a display Large font Tension Display with 4 additional lines 20 char acters per line and key pad or an HI 3300R blind remote stand alone PID controller swivel mounted with no display A remote 6 digit 7 segment LED display is available as an option for the HI 3300R The standard version has a single channel with a 2 channel option The HI 3300 Tension Controller is designed with output alarms for example e Low Tension e Hig
48. n front of Wrap Angle 2 Use the alphanumeric key pad and enter Wrap Angle 2 Press the Enter button to set the entry Press the button to move the cursor in front of Force Factor See Fig 2 40 If you did not enter values for Wrap Angle 1 or Wrap Angle 2 you enter the Force Factor if you know what it is If you entered values for Wrap Angle 1 and Wrap Angle 2 the force factor Force Factor cos Wrap Angle 1 cos Wrap Angle 2 is calculated for you and stored in non volatile memory If you don t know either wrap angles or the force factor the force factor is calculated when you do a traditional calibration and saved in non volatile memory HI 3300 Tension Controller 16 User s Guide 0 00 Wap Angle 2 60 0 gt Force Factor 0 998 Do C2 Cal CAL FIG 2 40 C2 CAL ENTERING FORCE FACTOR Step 19 Use the alphanumeric key pad and enter the Force Factor for your application Step 20 Press the down arrow button to move the cursor in front of Do C2 Calibration See Fig 2 41 Step 21 Wait 15 seconds for the scale to settle Step 22 Press the Enter button to complete the Calibration 222 0200 For ce Factor 0 998 gt Do Load Sensor Num FIG 2 41 C2 CALIBRATION Step 23 Cal Completed OK momentarily appears on the screen indicating the calibration was success ful message that says Function Error means that the calibration was not successful Check Chapt
49. ng touching it See Fig 2 1 Traditional Calibration From the Front Panel WARNING THE START BUTTON IS ACTIVE IN ANY MENU MAKE SURE THAT ALL PERSONNEL ARE CLEAR FROM ANY AND ALL MACHINERY WHEN CALIBRATING THE TENSION CONTROLLER ACCIDENTALLY STARTING THE SYSTEM WHEN IN THE CONFIGURATION OR CALIBRATION MENUS COULD CAUSE PROPERTY DAMAGE AND OR PERSONAL INJURY About Traditional Calibration Traditional Calibration is the method of calibration that uses test weights We recommend that the test weights total 2596 to 100 of the Maximum Tension for your application Make sure you know the exact weight See Fig 2 1 for the proper mechanical configuration for a Hard Cal Mechanical Calibration Setup for Traditional Cali bration Process Wrap Angles we Idler Roll Idler Roll Transducer Roll Known Weight FIG 2 1 CALIBRATION MECHANICAL SETUP Step You can press the Calibration 7 button to get directly to the Calibration Menu Step 2 An alternative is to Press the Setup 3 button The Setup Menu appears See Fig 2 2 0 00 Setup Inst Setup gt Calibration Security FIG 2 2 SETUP MENU SELECTING CALIBRATION Step 3 Press the button until the cursor is in front of Calibration See Fig 2 2 Step 4 Press the Enter button The CALIBRATION Menu appears with the cursor next to Snsr Type See 0 00 0 3 V 200106 Cal ibr ation Soft Cal gt Snsr Capacity
50. o connect to our demo unit by typing http H13300 hardinst com See Fig 3 21 Back gt A QSearch Favorites 22 Address http 168 215 209 78 FIG 3 20 BROWSER ADDRESS FIELD ENTERING IP ADDRESS Back gt a Search Favor http HI3300 hardyinst com FIG 3 21 BROWSER ADDRESS FIELD ENTERING H13300 HARDYINST COM Step 3 The HI 3300 Tension Controller Home Page appears See Fig 3 22 Tension Control Home Page Ma dy eat events etes DA ES NL FIG 3 22 3300 HOME PAGE SELECTING OPERATION Step 4 Click on Operation The Operation Menu appears See Fig 3 23 27 CHAPTER 3 Operating Procedures Operation Choose One Diagnostics UNE FIG 3 23 OPERATION SELECTING MONITOR Step 5 Tension Controller Microsoft Internet Explorer Click on Monitor The Monitor Dialog Box appears displaying the same information that is displayed on the front panel See Fig 3 24 12 06 04 10 12 22 E3 INSTRUMENT ID HI Web LATEST USER Operating Mode Manual Tension 0 1b Setpoint 18 1b Output 3 A D Conversion Error NOTE FIG 3 24 MONITORING THE HI 3300 You will notice a flickering on the monitoring page Browsers require frequent refreshing to dis play real time tension readings Therefore we have set a refresh for every 3 seconds Software Downloads for You
51. ol OPC enables an HI 3300 module to communicate with any device that supports OLE COM The architecture is designed to utilize the Microsoft distrib uted OLE technology to facilitate clients interfac ing to remote servers EtherNet IPTM Pending EtherNet IP short for Ethernet Industrial Protocol is an open industrial networking standard that takes advantage of commercial off the shelf Ethernet communication chips and media Ethernet technology enables the user to access device level data from the Internet The Ethernet IP network ing standard supports both implicit messaging real time I O messaging and explicit messaging message exchange EtherNet IP is an open network that takes advantage of com mercial technology that already exists TCP IP is the transport and network layer protocol of the Internet and is commonly linked with all Ethernet installa tions and the business world TCP IP provides a set of ser vices that any two devices can use to share data Because Ethernet technology and standard protocol suites such as TCP IP have been published for public use standardized software tools and physical media have been mass produced and are readily available offering you the benefits of known technology and accessibility The UDP IP User Datagram Protocol is also used in conjunction with the Ethernet net work UDP IP provides fast efficient data transport required for real time data exchange Modbus Over TCP I
52. on Controller 20 User Guide 2 ABC Button Enters the integer 2 in the display Also enters the characters A B C Pushing the button once enters the integer 2 NOTE For numeric entries only Push the button and the number on the button is entered NOTE For Alphanumeric entries only Pushing the but ton once the first letter on the button is entered in uppercase A D G and so on Push the button a second time the second letter is entered in upper case B E H K and so on Push the button a third time the third letter is entered in uppercase C ELL and so on Push the button a fourth time the fourth letter is entered in uppercase S Z Push the button a fifth time the first letter is entered in lowercase a d g and so on After you go through the lowercase letters you can push the button again for the number You need to push the buttons rapidly If you delay too long the instrument will accept the alphanumeric charac ter and move the cursor to the left preparing for the next alphanumeric entry This is true for all the Alphanumeric buttons If this occurs use the left arrow button to erase the current entry and enter another Setup 3 DEF Button This enables you to access the configuration and setup menus Also enters the number 3 and the letters D E F Taper 4 GHI Enables you to change Taper percentage on the fly when the controller is in the operating display Also enters the number 4 and the letters C H
53. ontains step by step instructions for operating the Hardy Instruments HI 3300 Tension Controller The proce dures include complete instructions for operating the Ten sion Controller from the Front Panel DeviceNet ControlNet Allen Bradley RIO and the Web Browser We highly recommend reading the procedures before operating the Tension Controller Being familiar with the operating procedures insures that the Tension Controller will provide trouble free service Getting Started Before operating the Hardy HI 3300 Tension Controller check to make sure the following procedures have been per formed e Power and Load Point cables properly installed e Communication cables properly installed e Calibration Performed e Setpoints entered All the features of the Tension Controller operate the same no matter what the interface First let s get familiar with operating the Tension Controller from the front panel of the instrument See Fig 3 1 Help About Help As you move through the setup configuration menus you may on occasion need assistance If you need help do the following Step 1 Use the up and down arrows and move the cursor in front of the Menu Item you want help on Step 2 Click the Help button either on the front Panel or Web Page and a Help Dialog appears The help dia log tells you what the Menu Item is used for or other descriptive information to help you enter the right parameters for the current menu item
54. ontrol Setup Dialogs Setup Dialogs enable the user to walk through the instrument set up On board Help files are just a key press or click away Mapped I O Mapped I O saves wiring costs by distributing the I O where you need it at the process or in the control room The con troller is a DeviceNet Scanner and the DeviceNet Scan table is configured using RS Networks Optional interfaces for Allen Bradley Remote I O Profibus and Analog provide communications to PLC and DCS systems WAVERSAVER Typically mechanical noise from other machinery in a plant environment is present in forces larger than the weight forces trying to be detected The HI 3300 is fitted with WAVERSAVER technology which eliminates the effects of vibratory forces present in all industrial weight control and measurement applications By eliminating the factor of vibratory forces the controller is capable of identifying the actual weight data WAVERSAVER can be configured from the front panel to ignore noise with frequencies as low as 0 25 Hz One of four higher additional cut off frequencies may be selected to provide a faster instrument response time The default factory configuration is 0 50 Hz vibration fre quency immunity C2 Calibration C29 Second Generation Calibration enables a web tension system to be calibrated electronically without using certified test weights which equals the systems load capacity A C2 weighing system consists of
55. ontroller a If there is power to the controller The front panel display should be lit b Ifthe display appears with a value the unit is ready for calibration 15 CHAPTER2 Calibration Step 2 Check to see that all communication and power cables are securely fastened to the connectors on the rear panel C2 Calibration From the Front Panel Step 1 Press the Setup 3 button The Setup Menu appears Step 2 Press the button until the cursor is in front of Calibration See Fig 2 33 0 00 Setup Inst Setup gt Calibration Secur it y FIG 2 33 CONFIGURATION MENU SELECTING SETUP Step 3 Press the Enter button The Calibration Menu appears with the cursor next to Snsr Type See Fig 0 00 0 3 V 200106 Cal ibr ation Soft Cal gt Snsr Capacity FIG 2 34 CALIBRATION SELECTING SENSOR TYPE Step 4 Press the Right or Left arrow buttons to select the sensor type The sensor types are categorized by the sensitivity of the Load Cell type which is posted on the load cell or with the load cell documentation Step 5 Press the Enter Button to set the entry Press the button until the cursor is in front of Capacity See Fig 2 35 0 00 0 3nV V 200105 Setup Snsr Type gt Capacity C2 Cal FIG 2 35 TRADITIONAL CALIBRATION ZERO VALUE Step 6 Use the alphanumeric key pad and enter the total capacity of all the load sensors used for your appli cation For examp
56. op to a preset low level to prevent brake lockup when the machine start the feature is actuated automatically upon loss of tension below a preset trip point by a change in machine speed or by an external contact closure A thin flat electrical transducer for measuring strain that is bonded to a body of inter est The material composition of a web A tension sensor and variation of a load cell specifically designed to measure exact web or filament tension in processing industry A controller feature that provides a relay contact closure at preset tension levels either high or low TLS is often used as a web break detector or web break deterrent A means of decreasing web tension as roll diameter increases in a rewind zone Taper tension helps produce a roll of better quality by eliminating telescoping crushed cores and overly tight or loose rolls A length of machine in which the web is under nominally the same tension usually between driven roller 3 Glossary of Terms TRACTION UNWIND ZONE WEB WRAP ANGLE One of the three possible web roller interactions where there is no relative movement between web and roller or between roll and roller Also refers to the maximum tension differential that can exist across a roller without slippage A tension zone created between a driven roll or driven nip and the core from which a roll is unwound Tension is often created by torque applied to the unwind shaft by a pneumatic brake
57. r HI 3300 Software downloads are generally done for one of the fol lowing reasons Publication of a Technical Bulletin Recommendation from Technical Support or Hardy Web Tech Step 1 In a web browser go to http www hardy inst com tension_control tension controller hi 3300 hardy tension controller to open the page shown in the following picture HI 3300 Hardy Tension Controller Precision Tension Control for Web or Strand Applications Application story with the Tension Controller at Georgia Tech published in the July 2005 issue of Converting magazine The Hardy Tension Controller incorporates an automatic closed loop process to provide precision control over the tension in the web or strand The controller incorporates either a single or dual sensor input to allow for tension measurements on either web rolls or strand pulleys The controller utilizes a PID algorithm to control tension in unwind rewind or intermediate zones The standard output from the Tension Controller is 0 10V 4 20 which nay to a brake 3 amp gt or a drive Hardy also provides email Webserver pneumatic systems to convert the analog output to a pneumatic signal for E air brake operation SMM WAVERSAVER Because the actual product tension is measured this type of precision control eliminates common process problems found in web and strand processes including feathering breakage telescoping wrinkling and
58. scellaneous DPD EDS Files GSD Files Profibus GSD Hardy Modbus Link Modbus Link FIG 3 26 DOWNLOADS PAGE Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 NOTE Step 9 Select the type of software to download Find and start the Auto Update exe program Click Find to search for and list the units that are online on this network Select the IP address of the unit you want to upgrade Click Browse to find and select the file you downloaded With both the IP address and file selected click Update When asked for a User Name enter hardy and for Password use updatepass all lowercase and click OK A percent complete bar will show the progress of the upgrade followed by a screen indicating the programming is complete If Update does not display the Password screen your program file may have too long of a path from the root directory Try moving your files up to your root directory and run again Cycle power on your HI 3300 HI 3300 Tension Controller User Guide 28 1 Glossary of Terms BASIS WEIGHT CD CALIPER THICKNESS CALIPER BRAKE TYPE CONVERTING CORE CORE SHAFT DANCER FEEDBACK FEEDFORWARD FILM FRICTION HOOKE S LAW IDLER ROLLER INTERMEDIATE ZONE LOAD CELL MANDREL MD GLOSSARY OF TERMS The mass per unit area of a web Common metric units are in g m 2 English units for the paper industry are often Ib 3000ft 2 Need to enter t
59. ted You must use the Instrument or Process Configuration in Setup to save parameters to non volatile memory Setpoint in Use Parameter About the Setpoint in Use Parameter The Setpoint in Use Parameter allows the user to view and or select the Product that is currently being processed There are three selections Prod 1 Prod 2 Prod 3 This parameter also enables the user to setup three tension setpoints for three different products in advance and select the setpoints at the time of process e For example you can set up three set points for Polyethylene Saran and Poly styrene Prod 1 Polyethylene 0 12 Ib Prod 2 Saran 0 15 Ib and Prod 3 Poly styrene 1 0 Ib As you process these webs you simply select Prod 1 Prod 2 Prod 3 with the proper tension setpoints NOTE The tension setpoints are typical running tensions yours may vary PARAMETER SETPNT IN USE RANGE PROD 1 PROD 2 PROD 3 DEFAULT PROD 1 0 00 Pr od 1 Pr oduct Prod3 gt Setpnt In Use Pr od 1 FIG 3 7 INSTRUMENT SETUP MENU SELECTING PRODUCT Step 1 Press the left or right arrow buttons to select Prod 1 Prod 2 or Prod 3 Step 2 Press the Enter button to set the entry Step 3 Press the button until the cursor is in front of Prod 1 See Fig 4 26 HI 3300 Tension Controller 22 User Guide Prod 1 Parameter About the Prod 1 Parameter The Product Menu enables the user to give the Process a name and set the tension setpoint
60. tional See Fig 3 14 HI 3300 Tension Controller 24 User Guide 0 00 PID Par ameter s Aut oCain gt Proportional 30 Int egr al 2 0 0 000 FIG 3 14 PID PARAMETERS SETTING PROPORTIONAL Step 2 Use the alphanumeric key pad and enter the new value Step 3 Press the Enter button to save the entry Step 4 Press the button until the cursor is in front of Integral Step 5 Use the alphanumeric key pad and enter the new value Press the button until the cursor is in front of Derivative Step 6 Use the alphanumeric key pad and enter the new value Step 7 Press the Enter button to save the entry Step 8 Press the until the cursor is in front of Auto Gain See Fig 3 15 AutoGain Parameter About the AutoGain Parameter The response required in controlling the winding or unwind ing of a large roll whether web or strand is different than that for a small diameter roll Due to the large inertia level of a large roll the controller will need to react more aggres sively than when controlling a small roll This equates to braking an 18 wheeler versus a pickup The multiplier func tions to make the control more aggressive for a large diame ter roll by increasing the Gain parameter for an increased output level Keep in mind that the output level is directly proportional to the Roll Diameter as expressed in the follow ing formula e Gain Gain Current Output x Multip
61. to your technical questions Just type in your question and see if your answer exists in our knowledgebase which is populated by interactions with cus tomers like you You can also create your personalized support page and your own support section that you can access 24 7 You can even view and update your entire call history as well as maintain your profile containing your product and system information so we can more effectively meet your needs Last but not least we invite all user feedback Click on the Provide Feedback link to let us know how we re doing What do you like about the product What s missing How do you like our new support site Anything Your comments are important and will help us shape the future direction of our products Connectivity All HI 3000 Series products enable the user to use the select able 10 100 base T Ethernet port or use its embedded web server to link performance diagnostics and setup data to and from your intranet extranet VPN or the internet Receive alarms via e mail or over WAP enabled devices including cellular phones and PDAs A DeviceNet interface allows multiple applications to be viewed and controlled from a dis play and additional 3rd party I O can be easily added to the filling dispensing system The HI 3300 includes a full line of network interfaces including e ControIlNet DeviceNet e Allen Bradley Remote Profibus Modbus e OLE Process C
62. vity 100 mV 50 mV 10 Ibs Sensitivity 50 mV 10 lbs Sensitivity 5 mV lb e Use the above for the sensitivity value Step 11 Press the Enter button to set the entry Step 12 Press on the button until the cursor is in front of Wrap Angle 1 See Fig 2 24 13 CHAPTER 2 Calibration SOFT CAL Sensitivity gt Wap Angle 1 W ap Angle 2 FIG 2 24 SOFT CALIBRATION MENU ENTERING WRAP ANGLE 1 Step 13 Use the alphanumeric key pad and enter Wrap Angle 1 for your application Step 14 Press the Enter button to set the entry Step 15 Press on the button until the cursor is in front of Wrap Angle 2 See Fig 2 25 0 00 30 0 30 0 0 1736 SOFT CAL W ap Angl e 1 WapAngle2 For ce Fact or FIG 2 25 SOFT CALIBRATION MENU ENTERING WRAP ANGLE 2 Step 16 Use the alphanumeric key pad and enter Wrap Angle 2 for your application Step 17 Press the Enter button to set the entry Step 18 Press on the button until the cursor is in front of Force Factor See Fig 2 26 0 00 30 0 0 1736 SOFT CAL W ap Angle 2 gt ForceFactor Do Soft Cal FIG 2 26 SOFT CALIBRATION ENTERING FORCE FACTOR NOTE Ifyou do not know Wrap Angle 1 or Wrap Angle 2 enter the Force Factor value Step 19 Use the alphanumeric key pad and enter the Force Factor for your application Step 20 Press the Enter button to set the entry Step 21 Press on the button until the cursor
63. y Instruments Tension Controller 1 Hardy Technical Support Technician 26 Hardy Web Site 1 Hardy Web Tech 1 3 Help 19 Help Button 19 Help Dialog 19 Help Dialogs 2 HI 3000 RC 4 HI 3300 1 HI 3300 Tension Controller 21 http www hardyinstruments com 1 Block 4 Module 4 Instrument ID 26 Integral 24 Interface 4 Internet World Wide Web 1 Intranet 1 IR Infra Red port 1 K Key Pad 1 Known Weight 7 L LED Display 1 Left Arrow Button 20 HI 3300 Tension Controller User Guide Load Cell Type 8 15 Load Cells 7 Load Point Cables 19 Load Sensor Number 15 17 M Manual or Auto Mode 19 Mapped l O 1 3 Maximum Tension 7 MB 4 Mechanical Calibration Setup for Traditional Calibration 7 Mechanical Noise 3 Method 2 Calibration 11 Method 3 Calibration Soft Cal 14 Millivolt Reading X2 12 Modbus Over TCP IP 5 MODBUS TCP IP 5 Model Number 26 Monitor Dialog Box 27 Monitoring the HI 3300 from the Web Page 26 Multiple Controllers 5 N Name and Tension Setpoint 23 NEMA 4X 4 OLE Technology DCOM 5 On Board Diagnostics 3 On board Help Files 3 Online Tech Support Knowledge Base 3 OPC 5 Operating Display 21 Operating Mode 20 Operating Mode Display 21 Operating the Tension Controller from the Front Panel 19 Options 4 Original Traditional Calibration 11 Output Alarms 1 P PB 4 PDA 1 Performance Diagnostics 1 PID Control 20 PID Control for Mid Process intermediate Zone

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