AC10 Measuring System P-2012-2 819-0402 Installation Instructions
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 System Overview. . . . . . . . . . . . . . . . . . . . . . . 3 AC10 Tensioncells . . . . . . . . . . . . . . . . . . . . . . 4 AC10 Electronics . . . . . . . . . . . . . . . . . . . . . . . 5 AC10 Specifications . . . . . . . . . . . . . . . . . . . . 6 Pushbutton Key Functions . . . . . . . . . . . . . . .
System Overview The AC10 Tension Measuring System is designed to measure tension on continuous strip processing lines and equipment. The system consists of two AC10 Tensioncells, the PSAC10 power supply amplifier board, and two cables for connecting the Tensioncells to the board. AC Linear Variable Differential Transformer (LVDT). Displacement of the LVDT core caused by variations in web tension results in an output signal to the PSAC10 board directly proportional to the applied tension.
AC10 Tensioncells AC10 Tensioncells are available in three capacity ranges for non-rotating shaft applications with maximum resultant force plus tare load of 60, 170, or 500 pounds respectively. The rugged, all-steel construction of the AC10 Tensioncell includes four basic components: the one-piece base block, the patented C-Flexure, the load plate, and the shaft support block. The factory-set mechanical stop provides overload protection up to ten times the maximum rated load capacity of the unit.
AC10 Electronics The AC10 microprocessor-based electronics adds ease of setup, versatility, and accuracy of the overall system by eliminating the need for potentiometers to adjust or setup the system. All adjustments and system settings are performed by using the pushbutton keys on the board. During setup, alphanumeric prompts are displayed on the 16-character LCD to guide the user through the setup procedure.
Specifications AC10 Tensioncells Dimensions (I x w x h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.00" x 3.44" x 3.90" Maximum Load Capacity (tension plus tare) AC10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 pounds AC10B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pushbutton Key Functions The six pushbutton keys on the PSAC10 board are used to enter and exit the Setup Mode and to make adjustments during the procedure. This section describes the various key functions and combinations that are used while setting up the system. RAPID RAPID The UP arrow key is used to toggle between selections. It is also used to incrementally increase the output voltage each time the key is pressed.
Installation The maximum rated load capacity must be greater than or equal to (RF + TW) where W = Tare Weight. The Web Resultant Force (RF) and Tare Weight are always summed. Refer to the Model Number Designation (Chart 1) below to verify the shaft diameter, and that the maximum rated load capacity of each unit. Pre-Installation Inspection Before installing the AC10 system: 1. Insure all components are present.
4. Drill a #6 (.204) hole concentric with the 1/4" hole in the locating tab. 5. Remove the Tensioncell to provide clearance to tap the hole for a 1/4-20 thread. 6. Repeat steps 2 through 5 for the Tensioncell for the other end of measuring roll shaft. 7. Loosen, but do not remove, the four screws in the bottom of the shaft support block enough to slide the Tensioncells on the roll shaft. Before installing the Tensioncells, refer to machine drawings, or other documentation to determine the mounting angle.
Electrical Installation Electrical Connections (Read the entire electrical installation procedure before proceeding.) Although either Tensioncell in the system can be designated as Tensioncell #1 or #2, the following electrical connections assume the AC10 Tensioncell marked W1 is Tensioncell #1 and the Tensioncell marked W2 is Tensioncell #2. The PSAC10 Power Supply/Amplifier board should be securely mounted in a cabinet or enclosure using the mounting holes and standoffs INPUT provided.
J2 to W2 Tensioncell Connection with Warner Electric supplied cable Terminal J2-1 J2-2 J2-3 J2-4 J2-5 Label Description Wire Color Sig Sig Exc Exc Gnd AC signal from LVDT AC signal from LVDT Excitation to LVDT Excitation to LVDT Shield Yellow Pink Brown White Shield Terminal J4-1 J4-2 J4-3 J4-4 Label Description 2L1 1L1 2L2 1L2 (Switched) Line 1 (Hot) Line 1 (Switched) Line 2 (Hot) Line 2 J3 Input Power (115/230 VAC, 1-PH, 50/60 Hz) Terminal Label J3-1 J3-2 J3-3 Description Wire Color Gnd Gro
The contact may be wired to function in either the normally open or normally closed state. J6 Analog Outputs Terminal The J6 terminal provides the connections for the two 10 volt DC outputs. Each output can provide up to 30 milliamp current. During setup, each output is individually scaleable to meet the requirements needed to calibrate the indicator, drive, or control connected to the board. The board circuitry is designed to allow a switch to be connected at Terminal J5.
4. Press ENTER when the desired mode is displayed. AC10 Setup Procedure Important: The input to any external device wired to J6-3 Out1 or J6-1 Out 2 must be 10 VDC or less. The following procedure assumes a digital voltmeter will be used when measuring and setting the desired output voltages. If the outputs are connected to a digital or analog indicating device, which will be used during normal operation, these devices may be used during the setup procedure.
7. Adjust Out 1 Note: All rolls used in the pull test should be free running rolls. 0% a. Connect a digital voltmeter between J6-3 Out 1 and J6-4 Gnd. b. Press the UP or DOWN arrow key (and RAPID key if necessary) until the desired no load output voltage is attained. c. Press ENTER. Output #2 ( -10 to +10 VDC) Common Output #1 ( -10 to + VDC) Common 1 Out 2 2 Gnd 3 Out 1 4 Gnd J6 8. Adjust Out 2 0% a. Connect a digital voltmeter between J6-1 Out 2 and J6-2 Gnd. b.
11. Adjust Out 2 100% a. Connect a digital voltmeter between J6-1 Out 2 and J6-2 Gnd. b. Press the UP or DOWN arrow key (and RAPID key if necessary) until the desired output voltage is attained. c. Press ENTER. 5. Press ENTER to select the desired mode. Note: The threshold may be set while the web machinery is in operation. Although the LCD will not be showing the tension, Output #1, Output #2, and the serial output will still be responding to tension changes.
Troubleshooting When properly installed in accordance with the design specification and procedures outlined in this manual, the AC10 Tension Measuring System should require little or no regular maintenance or service. Certain conditions, however, can impair the accuracy, reliability, and performance of the system. The following are some conditions to consider which may effect the mechanical and/or electrical components of the system. 1. Have the system operating parameters changed? 9.
a. Using an AC volt meter with at least 5Khz band width, measure the voltage between J1-3 Exc and J1-4 Exc. The meter should read 15Vrms ~ 5Khz ± 5%. If excitation voltage is low, turn off power to the board and remove the J1 connector. Turn power back on and recheck. If voltage is correct, check for a short in Tensioncell cable assembly. Repeat test for Cell #2 at J2. b.
AC10 Tensioncell Dimensional Drawings 3.00 .75 2.00 .50 + 3.13 3.90 1.13 2.00 See Note .25 1.44 1.31 .25 Dia. Hole For Locking Screw 2.50 1.13 2.13 5/8-11 UNC .93 Full Th’d for Mounting Bolt 3.44 Note: Stainless steel self-aligning bushing provided for 1/2” to 1-1/2” diameter shafts in 1/16” increments. W2 unit shown here. W1 unit is available. Electrical Connector (Specifications and dimensions subject to change without notice.
PSAC10 Board Dimensions 1.31 6.88 6.25 .31 .25 Mounting Holes .250 Dia. (7) Places 5.75 3.13 J3 3.13 J4 J6 8.75 8.25 J5 W arner Part# PSAC10 Serial# Setup Rapid Exit Setup J7 Enter J8 J1 J2 J9 Specifications and dimensions subject to change without notice.
Warranty Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any product manufactured and sold by it which proves to be defective in material or workmanship within a period of one (1) year from the date of original purchase for consumer, commercial or industrial use. This warranty extends only to the original purchaser and is not transferable or assignable without Warner Electric LLC’s prior consent. Warranty service can be obtained in the U.S.A.
