UNWIND BRAKE TENSION CONTROLLER MWP – 12662 - 0 Instruction Manual AO-70173 (Rev BA)
Table Of Contents General Description ............................................................................................................. 4 Unwind Brake System ..........................................................................................................................4 Motor Powered Unwind System ...........................................................................................................4 Quickstart ....................................................................
Table Of Contents "Soft Start”.......................................................................................................................... 19 Operating ............................................................................................................................ 20 Adjusting the screen contrast .............................................................................................................20 Change Passwords ..........................................................
WebPro Unwind Brake Tension Controller General Description The WebPro Digital Tension Controller is part of a closed loop tension control system with transducer feedback. The Controller continuously controls the web tension to the TENSION SET POINT value and displays the true web tension on an LCD screen, either as a percentage or in engineering units. The screen will display the tension applied to each transducer separately by pressing the < LEFT tension or > RIGHT tension key.
WebPro Unwind Brake Tension Controller Quickstart The Controller is supplied with the software loaded for the application as ordered but it will require commissioning before use. For more detailed information refer to the various sections later in this manual. 1. Carefully unpack the Controller, remove the rear cover and detach the bag containing the accessories. Attach the cable gland to the large hole in the rear cover. Mount the Controller in the operators panel using the two keyhole brackets provided.
WebPro Unwind Brake Tension Controller Installation The following parts are supplied:1. Controller, with software loaded for the application but requiring commissioning by the user. 2. Two keyhole mounting brackets. 3. Cable gland to be fitted to the rear cover and header connector kit for encoders. 4. Cabinet, if ordered. 5. Electro-pneumatic (E/P) Converter kit or High Current Driver, if ordered. 6. Manual (this document).
WebPro Unwind Brake Tension Controller Before connecting the HCD to the mains supply, ensure that the mains voltage matches the HCD requirements. Connect the HCD control input common to the WebPro controller “0V analog” mTB4 and the HCD control + signal input to the WebPro controls “control out 0/+10V” or TB4. Caution: The HCD controller signal input connections must be isolated from the mains supply connections or damage to the WebPro and the HCD will occur.
WebPro Unwind Brake Tension Controller cables and other cables through the most convenient holes in the rear cover and connect to the terminals. Replace the rear cover and secure the cable gland to retain the mains cable for safety purposes. All the Controller 0V commons, analog and digital, are connected to earth E and to the metal case.
WebPro Unwind Brake Tension Controller Transducer Connections The Controller may be used with one half bridge transducer, two half bridge transducers, one full bridge transducer or two full bridge transducers. The strain gauges may be semiconductor with 5.6V or 10V DC excitation, each half bridge resistance 230S minimum; or foil with 10V DC excitation, each bridge resistance 350S minimum.
WebPro Unwind Brake Tension Controller Machine Sequence Logic and Connections, Digital Inputs WARNING - Do NOT connect the digital inputs to a negative or AC supply, this will cause damage and will invalidate the warranty. The digital inputs are opto-isolated and over voltage protected. The maximum input voltage is +24V DC. The MAN/AUTO/OFF functions may be selected from the keypad if Enable MAN/AUTO/OFF keys is Enabled.
WebPro Unwind Brake Tension Controller Power Supply Connections The Controller may be powered by 110-120V, 220-240V 50/60Hz AC at 15VA or by 22-26V DC at 1A. Before connecting the Controller to the mains ensure that the mains voltage selector switch is set correctly. The mains supply is terminated on TB1, a two-part connector. The mains fuse F1 is 160mA. The 24V DC supply must be smooth and free from noise. The 24V supply is terminated on TB4; positive to pin 1, negative to pin 2.
WebPro Unwind Brake Tension Controller Batch Hold This feature is used when winding small rolls from one large parent roll, as for cash register or till rolls where the machine stops and starts frequently. When enabled and the input is operated, the output level from the Controller is held in memory on slow down and the Controller output starts from this level when the input is released. This prevents a tension dip due to the normal operation of the "Soft Start" feature.
WebPro Unwind Brake Tension Controller Press 4 Enter the Commissioning password 5678 ( factory default ) and then press ENTER Commissioning Menu 1. Machine parameters * 2. Calibrate tension * 3. Calibrate speed * 4. Adjust PI stability * 5. Change passwords * 6. Diagnostics * An asterisk * indicates that a further menu will open if this item is selected.
WebPro Unwind Brake Tension Controller Remember to press the CONFIRM key, otherwise the parameters will not be saved to the memory. Note Start in Control Screen The Controller is despatched with this item set to "No". We recommend that after all commissioning is finished that this is then set to "Yes". When the Controller is now switched on, the program is loaded, the company logos are shown briefly and then the Control or operating screen ready for use by the operator.
WebPro Unwind Brake Tension Controller TB4/11 is an open drain mosfet which may be used with a suitable electrical relay to select the pads of a multipad brake or when the Controller is in Torque Control to select the motor torque range. See Digital Output Connections for more details. Minimum tension Enter a value, the minimum tension is 3%, the maximum is 20%. The system may not function correctly and may be unsafe if it is operated at zero tension (the motor may run forwards).
WebPro Unwind Brake Tension Controller Line Tacho or Encoder * For Unwind Brake mode this input is may be used to improve the system performance while the machine is accelerating and decelerating. The system will operate quite well without this feature provided the acceleration or deceleration rate is not excessively fast. If an encoder is selected enter the maximum number of pulses per second when the machine is at maximum speed. This allows for the encoder pulses per revolution and the gear ratio used.
WebPro Unwind Brake Tension Controller Press the SET UP key to return to the Commissioning menu Calibration aborted This is shown if the SET UP key is pressed during the calibration. The Controller will return to the Commissioning Menu screen. The controller has not been calibrated or the settings are no longer valid. Press any key to continue. Calibration of the Total Tension Analog Output The Total Tension analog output provides 0 to +10V at 2mA for a remote meter or chart recorder.
WebPro Unwind Brake Tension Controller Product Parameters The default is Product Number 1.
WebPro Unwind Brake Tension Controller Access the Adjust PI stability menu from the Commissioning menu. Run the machine with the Controller in Auto at a Tension Set Point of approximately 50%. Use the SCROLL keys to select the parameter to be changed and adjust the parameter using the numeric keys or the +/- keys. Press the CONFIRM key to implement and save the change.
WebPro Unwind Brake Tension Controller Operating A typical Control screen is shown below. The maximum rate of change of the manual output is determined by the "Set point ramp rate" value. The Set Taper key does not operate. The Manual feature is only available in Unwind Brake mode. The Auto Tension set point may be set with the numeric keys followed by ENTER or by the +/- keys. The analog tension set point triangle is only visible when the Controller is in Auto control.
WebPro Unwind Brake Tension Controller revert to the previous valid input. The Controller has been designed to meet UL and CSA requirements. The Controller is self-certified as compliant with the EC Low Voltage Directive 73/23 and is CE marked. The Controller is self-certified as compliant with the EC EMC Directive 89/336. However the EMC performance will depend on the installation and environment and CMC Inc can give no guarantee that the installation will be free of problems.
WebPro Unwind Brake Tension Controller Installation Record Sheet Installation Date: Customer Address Machine name or type Purchase Order No. Controller Application System Units Output Range Tension Range Low High Minimum Tension Ramp Rate Damping Time Display Precision Friction Static Dynamic Tacho Yes / No Stop Time Product Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Material Passwords Supply Voltage Stability Prop Integral Set Up ....................
