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Ultrasonic Tension Controller Model UTC-1, -2
Installation Instructions
PROPORTION-AIR, INC. BOX 218 MCCORDSVILLE, IN USA 46055 PHONE: (317)335-2602 FAX: (317)335-3853
web site: www.proportionair.com email address: [email protected]
The UTC-2 Controller consists of (2) UTC-1 Controls in a single enclosure. For calibration purposes, each UTC-1 unit must be done individually.
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UTC 7/26/06 DC
OPERATION The US1 continuously measures the roll diame-ter and sends the information to the controller. The controller uses the diameter measurement along with preprogrammed core and full roll information to supply the proper pressure out-put to the pneumatic brake or clutch using the QB control valve. This output is proportional to the diameter and scaleable to the desired ten-sion. Once the operator sets the tension level via the “AUTO” control knob, the output is automatic and the proper tension is maintained roll after roll. DESCRIPTION
The UTC Ultrasonic Tension Controller package from Proportion-Air provides auto-matic tension control on any unwind or re-wind process where diameter compensated control is required.
US1 ultrasonic sensor ♦ Field adjustable ♦ Detect objects up to 37 feet
UTC Controller ♦ Mounted in a NEMA 12 enclosure
(control box) or panel version ♦ Build up/down ratio is set by use of a dip-
switch ♦ Light emitting diodes (LED’s) to visually
indicate when core (zero) and full roll (span) adjustments are correct
QB Series valve ♦ Closed loop control ♦ NEMA 4 enclosure ♦ CE approved ♦ Can be mounted in any position ♦ Field calibratable ♦ Comes standard with an analog output
COMPONENTS:
FEATURES ♦ Easy to install, takes only few minutes. ♦ Quality assurance can be verified using the
analog monitor output on the QB valve ♦ Roll Diameter Compensation ♦ Unwind/Rewind tension zones ♦ Sonic input provides non-web-contact:
Ideal for sensitive web ♦ Follower arm input ♦ Diameter calculator input ♦ Easy setup: On-board LED’s indicate cor-
rect setup adjustments ♦ Automatic or manual mode ♦ Space saving: up to 4 controllers in one
enclosure ♦ Adjustable taper tension (rewinds) ♦ Adjustable output limit ♦ Adjustable minimum core preset
TYPICAL APPLICATIONS Materials Processes Paper Printing Plastics Coating Foils Laminating Cardboard Slitting Textiles Cutting Rubber Embossing Linoleum Punching Steel Perforating
UTC ULTRASONIC TENSION CONTROLLER
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UTC 7/26/06 DC
DIMENSIONS
Electrical AC Supply……………...………..115 volts at .5 amps Input diameter signal…..………….0 to + 10 volts DC Zero range (core)……….50% of input diameter signal Span range (full roll)……………………………..25:1 Sonic excitation….……0-24 volts DC at 75 milliamps Follower arm excitation…...…………….+10 volts DC Follow arm pot value…..……………….....10 K ohms System accuracy Electric*…………..……..2% typical System accuracy Electro/Pneumatic…......0.2% typical Operating Conditions Ambient Temperature…………………...……..0-40ºC Weight Single enclosure version…………...……..……..8 lbs. Single panel version………………………..……2 lbs.
* Total system accuracy depends on the mechanical condi-tions of your machine (shafts, bearings, spindles, etc.) as well as the type of clutch or brake you select.
SPECIFICATIONS
Options ♦ Open chassis mounting available ♦ Multipack systems available ♦ 4 to 20mA control output ♦ Panel meter displays output level ♦ 115/230 volts AC, 50/60 Hertz available ♦ Reverse acting diameter signal ♦ Inertia compensated E-STOP
ORDERING INFORMATION
*CONSULT FACTORY FOR OPTION NUM-BERS, NON STANDARD BOARDS AND METH-ODS OF MOUNTING
UTC -1 -080 Sxxxx
MODE MAXIMUM CALI-BRATED
SPECIAL
1=SINGLE BOARD
EXAMPLES 000=NO CONTROL VALVE 080=0-80PSIG OPTIONS for pressure ranges not starting at “0”
BLANK=NO OP-
SE-
UTC (Single enclosure version)
UTC-PV (Panel version)
UTC-1, 2 Installation Instructions 1. Introduction 2. Principle Features 3. System Operation 3.1 How the system works 4. Ultrasonic Sensor Setup Procedure 5. Roll Build Up/Down Ratio Setup Procedure 6. Calibration Procedure for Controller #1 6.1 Calibration Procedure for Controller #2 7. Manual and Automatic Operation 7.1 Manual Operation 7.2 Automatic Operation 8. System Configurations 8.1 UTC-1 With Drive Packages 8.2 UTC-1 With Pneumatic Output 8.3 UTC-1-EO With Electric Output 8.4 Output Limit 9. Isolated Output 9.1 PCM4 Isolated Output (Optional) 10. Taper 10.1 Why is Taper needed? 10.2 Taper (Internally Generated) 11. Minimum Core Preset (Offset) 11.1 Why is it needed? 12. Fuses 13. Troubleshooting 13.1 Power Supply, D10 Board 13.2 Control Circuitry, D10 Board 13.3 Electric Output, PS10 & E10 Board Schematics and Wiring Diagrams
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MODEL UTC-1, 2 TENSION CONTROLLER Table of Contents
1. Install the Ultrasonic Sensor in accordance with Section 4 (page 3) of this instruction man-ual. Verify that the Sensor is aligned correctly with the target. (See the wiring diagram at the end of the instruction manual). 2. Mount the controller to a surface that is free from excessive heat and vibration and where the operators’ devices are easily accessible. 3. If an air brake is used: Mount the E/P converter (VP-1) as close to the air brake as possible and make the appropriate air connections to the unit. Insure that the air supply is clean (a 5 ucron filter is re-quired) and dry, and is between 80 and 120 PSI. The signal wires from the UTC-1 controller should be shielded cable and grounded only at the UTC-1 end. (See wiring diagrams at the end of the instruction manual). If an electric brake used: See wiring diagrams at the end of the instruction manual for proper wiring into the electric brake/clutch. 4. Please note that all terminal blocks are detachable. Remove the blocks for easy wiring and then reseat them onto their appropriate headers. 5. If there are any ribbon cable connectors make sure they have not came loose during ship-ping. Insure that the correct AC input is applied. See the serial tag for the correct voltage rat-ing. 6. Refer to section 5 (page 4) for roll build up/down setup procedure. 7. Apply AC power to the unit. Turn the power switch on. At least (1) of the LEDs located on the board will illuminate. 8. Refer to section 6 (page 6) for roll core and full roll calibration procedure. 9. Turn TENSION switch ON. Select AUTO. Adjust the AUTO pot for the desired running tension level. Note: Fully CCW rotation corresponds to zero output and fully CCW rotation corresponds to maximum output. 10. Other features of the controller maybe activated if required. Refer to appropriate sec-tions of the instruction manual for more information.
UTC-1, 2 INSTALLATION INSTRUCTIONS
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1. INTRODUCTION The UTC-1 Ultrasonic Tension Controller is an analog designed automatic tension controller. Automatic tension control is achieved by accurately measuring roll diameter using an ultrasonic sensor. The diameter signal is then processed to produce a proportioned output (based upon roll size) which in turn energizes the torque device (such as a brake, clutch, or drive etc.). All signal processing and circuitry is contained on a computer designed, printed, circuit board. Each board contains 2 separate controllers on it so that two separate tension zones may be con-trolled at the same time. The controller is extremely user friendly in that only one control knob (AUTO) is required to adjust the automatic tension level of the system. The UTC-1 controller is contained in a rugged steel enclosure suitable for industrial service or as a panel version to be mounted in the customers own console. All terminal blocks are detach-able to simplify installation and facilitate board replacement. 2. PRINCIPLE FEATURES 1. Fast accurate tension control throughout the unwinding/rewinding process to provide uniform control response over roll diameter changes. 2. Non-Web-Contact: Ideal for sensitive films and foils. 3. Automatic control with manual override. 4. An adjustable minimum core preset. 5. Easy installation and setup: On board LEDs indicate correct setup adjustments. 6. Space saving: 2 separate controllers per board. 7. Edgewise meter displays output level. (Optional) 8. 4 to 20 MA control output. (Optional) 9. Adjustable taper tension.
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3. SYSTEM OPERATION The UTC-1 is part of an open loop tension control system with roll diameter compensation. Other components of the system include the ultrasonic sensor and the brake or clutch (a torque device). 3.1 HOW THE SYSTEM WORKS
The operator sets the desired tension using the AUTO pot. The ultrasonic sensor accurately produces a voltage signal that is proportional to roll diameters. The roll diameter signal is then calibrated by the controller to match the roll’s build up/down profile. The UTC-1 automatically regulates its output to the brake or clutch to maintain the desired tension level. Because this system operates in an open loop configuration, instability and hunting problems (prevalent in many closed loop systems), caused by heavy out-of-round rolls and/or large inertia components are eliminated with this system. 4. ULTRASONIC SENSOR SETUP PROCEDURE 1. Ultrasonic sensors are designed to operate within a certain minimum and maximum distance range. a. Motion’s Sensor MTSS-1 has a target range of 4" to 40" b. Motion’s Sensor MTSS-1 has a target range of 8" to 80" 2. The UTC-1 has been designed to offset (zero out) 50% of the sensors output signals to achieve proper core calibration. This means that the minimum and maximum distance the sensor may be positioned form the empty roll (core) is: a. Distance for Sensor MTSS-1 is between 20" and 40". b. Distance for Sensor MTSS-2 is between 40" and 80". NOTE: If, because o space requirements, it is necessary to position the sensor closer to the core ( than the minimum and maximum distances stated above) then it will be necessary to adjust SPAN Pot P2 (located on the sensor) until core calibration can be achieved. SPAN Pot P2 should only be adjusted if the sensor cannot be mounted as stated above.
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3. Of course, once the sensor has been positioned correctly for the core distance, the roll may now build up until the roll diameter is as close to the sensor as: a. Closes distance to Sensor MTSS-1 is 4" b. Closes distance to Sensor MTSS-2 is 8" 4. The wiring diagrams at the end of this instruction manual show the sensor to be wired to produce an inverted analog output signal meaning that the output voltage value decreases w i t h distance from the target.
NOTE: The UTC-1 has been factory configured to accept this inverted signal from the sensor. The UTC-1 may be factory configured (upon request) to accept a non-inverted signal from the sensor meaning that the voltage value increases with distance from the target. 5. Most sensors have adjustable zero and span capability. Because of the way the UTC-1 controller has been designed, in most cases (assuming the sensor has been factory adjusted for minimum and maximum target range) adjustments of these pots are not necessary.
NOTE: These pots should only be adjusted if system calibration cannot be achieved. 6. Refer to the sensors instruction manual for more information or if adjustment is necessary.
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Ratio
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2
3
4
5
6
7
8
9
10
1.5
I
O
O
O
O
O
O
O
O
O
2
O
I
O
O
O
O
O
O
O
O
3
O
O
I
O
O
O
O
O
O
O
4
O
O
O
I
O
O
O
O
O
O
5
O
O
O
O
I
O
O
O
O
O
6
O
O
O
O
O
I
O
O
O
O
8
O
O
O
O
O
O
I
O
O
O
10
O
O
O
O
O
O
O
I
O
O
12
O
O
O
O
O
O
O
O
I
O
16
O
O
O
O
O
O
O
O
O
I
5. ROLL BUILD UP/DOWN RATIO SETUP PROCEDURE To simplify installation of the system the roll build up/down ratio (roll profile) is programmed into the controller via the dip switch SW1 SW1 Switch Programming
I = ON O = OFF
Use the following procedure to determine the proper ratio setting: 1. Measure the diameter of the minimum core size to be used. (CORE) 2. Measure the diameter of the maximum full roll to be used. (FR) 3. Roll build up/down ratio is determined by dividing the full roll (FR) by the core (CORE). FR RATIO = CORE 4. Use dip switch SW1 to enter in the correct ratio value. Note: Round up to the next higher selectable value if the calculated value is greater than 50% of the difference between the two selectable values. Round down to the next lower selectable value if the calculated value is less than 50% of the difference between the selectable values.
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Example #1: CORE = 3" FR = 36" FR 36" RATIO = CORE = 3" = 12 From chart select switch position 9. Example #2: CORE = 3.5" FR = 16" 16 RATIO = 3.5 = 4.57 From chart select switch position 5. Position 5 was chosen by rounding 4.57 up to the next available value (5). Example #3: CORE = 6" FR = 20" RATIO = 20 =3.333 6 From chart select switch position 3. Position 3 was chosen by rounding 3.33 down to the next available value (3).
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6. CALIBRATION PROCEDURE FOR CONTROLLER #1 1. Verify that the sensor is installed and aligned correctly with the roll. It is important to direct the sensor at the core of the diameter being sensed, otherwise false readings will result. 2. Place an empty roll on the unwind/rewind stand. (core condition) 3. Adjust CORE pot R44 CW until BOTH core LED indicators (LED 2, LED 3) are both off (not illuminated). Refer to Section 4 (page 3) if this adjustment cannot be achieved. 4. Place a full roll (maximum diameter roll) on the unwind /rewind stand. 5. Adjust FULL pot R42 CW until the full LED indicator (LED 1) just illuminates. Make sure FULL roll pot R42 is adjusted just at the point where the full LED indicator (LED 1) just goes on (illuminates). 6. For the best results, repeat steps 2 - 5 to ensure that core and FULL roll conditions are re-peatable.
6.1 CALIBRATION PROCEDURE FOR CONTROLLER #2 1. Verify that the sensor is installed and aligned correctly with the roll. It is important to direct the sensor at the core of the diameter being sensed. Otherwise, false readings will result. 2. Place an empty roll on the unwind/rewind stand. (core condition) 3. Adjust CORE pot R47 CW until both CORE LED indicators (LED 5, and LED 6) are both off (not illuminated). Refer to Section 4 (page 3) if this adjustment cannot be achieved. 4. Place a FULL roll (maximum diameter roll) on the unwind/rewind stand. 5. Adjust Full pot R45 CW until the FULL LED indicator (LED 4) just illuminates. Make sure FULL roll pot R45 is adjusted just at the point where the FULL LED indicator (LED 4) just goes on (illuminates). 6. For the best results, repeat steps 2 - 5 to ensure that CORE and FULL roll conditions are repeatable.
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7. MANUAL AND AUTOMATIC OPERATION The UTC-1 controller may be operated in the manual or automatic mode of operation.
7.1 MANUAL OPERATION The manual mode of operation is simply activated by switching the AUTO/MANUAL switch to auto. The MANUAL pot sets the amount of output to the brake/clutch. When TENSION is switched off, the controller’s output is deactivated and releases the brake/clutch.
7.2 AUTOMATIC OPERATION The automatic mode of operation is simply activated by switching the AUTO/MANUAL switch to auto. The automatic tension level is set by adjusting the AUTO pot. During the unwinding/rewinding process the output level is changed automatically by the controller to compensate for the changing roll size. When TENSION is switched off, the controller’s output is deactivated and releases the brake/clutch.
8. SYSTEM CONFIGURATIONS The UTC-1 controller may be integrated with other control packages to produce the desired ten-sion control package (system). The three basic system configurations are: 1. UTC-1 controller interfaced with drive packages. 2. UTC-1 controller used with the VP-1 (pneumatic converter) to control air brake/clutches. 3. Model UTC-1-EO controller which has a SCR controlled Electric Output (EO) circuit to
control electric brake/clutches directly. 8.1 UTC-1 WITH DRIVE PACKAGES The UTC-1 controller interfaces into drive packages used in unwind/rewind applications. The drive package is slaved to the UTC-1 controller where all the signal processing takes place. CAUTION!!! The circuit common of the UTC-1 is connected to earth ground. Make sure that the common of the drive can be connected to earth ground. If not, use isolation modules to con-nect between the systems.
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Here’s how the system works: 1. Usually the drive package is configured to operate in the torque mode. 2. The control output signals from the UTC-1 controller are fed into the current limit input of the drive package. 3. The operator sets the desired tension using the AUTO pot. The drive package produces torque (results in web tension) based upon the setting of the AUTO pot. The UTC-1 automati-cally regulates the torque being produced by the drive package to compensate for the changing roll size thus maintaining the desired tension level throughout the process.
8.2 UTC-1 WITH PNEUMATIC OUTPUT The UTC-1 controller may be used with the VP-1 Pneumatic Converter to control air brake/clutch. Here’s how the system works: The operator sets the desired tension using the AUTO pot. The electric brake/clutch produces torque based upon the setting of the AUTO pot. The UTC-1 automatically regulates the voltage to the brake/clutch to compensate for the changing roll size thus maintaining the desired tension level throughout the process.
8.3 UTC-1-EO WITH ELECTRIC OUTPUT The model UTC-1-EO has an SCR regulated Electric Output (EO) to directly interface and con-trol electric brake/clutches. Here’s how the system works: The operator sets the desired tension using the AUTO pot. The air brake/clutch produces torque based upon the setting of the AUTO pot. The UTC-1 automatically regulates the volt-age to the brake/clutch to compensate for the changing roll size thus maintaining the desired tension level throughout the process.
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Here’s how the Electric Output (EO) works: The processed 0VDC to a +10VDC output signal from the D10 board is fed into the PS10 board. The PS10 in turn processes the signal into a SCR control signal. The SCR control sig-nal is then fed into the E10 board where it is converted into a SCR controlled output. Using pot R1 (located on the PS10 board) the output to the brake/clutch is adjustable from 24VDC to 90VDC with a maximum current output of 4 amperes. Even at low output values a special lin-earization circuit keeps the SCR controlled output voltage linear and proportional to the input signal from the D10 board. The brake/clutch is connected between terminals TB2-B1 (+) AND TB2-B2 (-) on the E10 board. CAUTION: Brake/clutch output is isolated from earth ground. All wiring to the brake/clutch must be insulated from earth ground. 8.4 OUTPUT LIMIT The maximum output of each configuration as described in Section 8 is adjustable from mini-mum to maximum using the OUTPUT pot. This pot may be used to: 1. Limit the maximum torque (or Tension) setting of the system. 2. Tailor the controllers output to be compatible with another piece of equipment. 9. ISOLATED OUTPUT System (or output) isolation is required when the circuit common of the drive package is float-ing and/or cannot be connected to earth ground. The circuit common of the UTC-1 controller must be connected to earth ground to eliminate possible sensor damage.
9.1 PCM4 ISOLATED OUTPUT (OPTIONAL) The UTC-1 controller offers an isolated output for customer use via the PCM4 isolation board. The PCM4 board provides optical isolation between the UTC-1 controller and the drive pack-age being used.
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10. TAPER Taper is an extremely useful and highly recommended feature for rewind applications. 10.1 WHY IS TAPER NEEDED? Taper tensioning is used to eliminate a number of winding problems such as crushed cores, roll shifting, telescoping, and to create the desired tension profile as the roll builds up. Taper ten-sioning itself is simply the process of decreasing the rewind tension level at a constant rate pro-portional to the increasing roll size. In most rewind applications a total taper tensioning value of 10% to 20% from core to FULL roll will provide the necessary tapering. There are some cases where a 50% to as much as 100% (constant torque) tapering is required to create the nec-essary tension profile. 10.2 TAPER (INTERNALLY GENERATED) The UTC-1 controller produces an internally generated taper function for customer use. The amount of taper is adjustable from 0% (TAPER pot fully CCW) to 100% (TAPER pot fully CW). Zero taper represents constant tension as the roll builds up and 100% taper represents constant torque as the roll builds up. This is how the circuit works: The Sonic Controller accurately measures roll diameter. This diameter signal is then compared to the programmed roll build up ratio. The resulting proc-essed signal is used to automatically decrease the controllers output proportionally to roll size and the setting of the TAPER pot. Controller #1 Taper is activated by: 1. Remove the jumper wire between TB3-10 and TB3-11. 2. Place a jumper wire between TB3-10 and TB3-8. 3. Use TAPER pot R38 to adjust taper. Controller #2 Taper is activated by: 1. Remove the jumper wire between TB4-10 and TB4-11. 2. Place a jumper wire between TB4-10 and TB4-8. 3. Use TAPER pot R41 to adjust taper.
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11. MINIMUM CORE PRESET (OFFSET) The UTC-1 controller may be adjusted so that a minimum fixed value of output is always pre-sent on the controller’s section.
11.1 WHY IS IT NEEDED? There are 2 main reasons: 1. It may be desirable to always have a minimum amount of fixed tension in the process so that under no circumstances could the web go slack. This eliminates possible wrap arounds on idler and pinch rolls. 2. The UTC-1 controller may be used with another piece of equipment. It’s possible that the input section of the equipment might characteristically be designed with a dead zone near zero. This means it requires a certain amount of input just to overcome the dead zone before the equipment starts to respond to the signal. The UTC-1 controller’s output may be offset from zero to a point to just overcome the dead zone value. NOTE: Any offset value is always present on the output of the controller. The TENSION ON-OFF SWITCH deactivates the control signal, but does not deactivate the offset value. Output offset for Controller #1 is adjusted by OFFSET pot R36. Output offset for Controller #2 is adjusted by OFFSET pot R39.
12. FUSES 1.The UTC-1 controller contains 1 fuse. The fuse F1 is located at the top right hand side of the D10 board. This fuse is .5A/250V fast acting, Littlefuse #312.500. 2. The UTC-1-EO controller contains 4 fuses. One fuse is located at the top right hand side of the D10 board. This fuse is .5A/250V fast acting, Littlefuse #312.500. The other 3 fuses are located on the right hand side of the E10 board. These fuses are 4A/250V fast acting, Littlefuse #312.004.
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13. TROUBLESHOOTING Improper operation of the UTC-1 may be due to failures in external equipment associated with the UTC-1, external inputs and contacts, or in the controller itself. If the problem is diagnosed as a circuit board failure the board should be returned for repair or replacement. Failures en-countered during installation are usually quite different from the failures experienced after the UTC-1 has been operated successfully for a period of time. Installation problems are most likely due to improper connection of external devices, improper calibration or tuning, and/or mechanical problems within the machine. 13.1 POWER SUPPLY, D10 BOARD If any problem is encountered with the UTC-1 verify that at least one of the LEDs are on. If all of the LEDs are off check the fuse or fuses and the integrity of the AC power source. Using a VOM or digital volt meter check the following power supplies located on the board. 1. +15 VDC supply (+ .6VDC)
Check between P4-1(+) and P4-4 (common). 2. -15 VDC supply (+ .6VDC)
check between P4-6 (+) and P4-4 (common).
13.2 CONTROL CIRCUITRY, D10 BOARD The following tests will determine if the control circuitry of the D10 board is ok. If the D10 board fails any of these tests it should be returned for repair or replacement. 1. Go back to Section 6 (page 5) of this manual and verify that the calibration procedure can performed and is ok. 2. Please perform the following setup: a. AUTO/MANUAL switch at AUTO b. TENSION ON/OFF switch ON c. AUTO pot fully CCW d. OFFSET pot (on circuit board) fully CCW e. OUTPUT pot (on circuit board) fully CCW f. TAPER pot (on circuit board) fully CCW
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g. Place a full roll on the stand. h. The voltage between TB3-7 (+) and TB3-6 (common) should be 0VDC (+ .1VDC). 3. Set the AUTO pot fully CW. The voltage between TB3-7 (+) and TB3-6 (common) should be +10VDC (+ 1VDC). 4. Manual check (if applicable) : a. AUTO/MANUAL switch at MANUAL. b. MANUAL pot fully CCW. The voltage between TB3-7 (+) and TB-6 (common) should be 0VDC (+ .1VDC). c. MANUAL pot fully CW. The voltage between TB3-7 (+) and TB3-6 (common) should be +10 VDC (+ 1VDC). This completes the troubleshooting for the D10 board. Because the D10 board is complex it is impossible to test each circuit and feature at this level of testing. If you have any questions as to the boards performance it may be wise to return it for repair or a replacement. 13.3 ELECTRIC OUTPUT, PS10 & E10 BOARD The following test will determine if these boards are O.K. If these boards fail any of tests they should be returned for repair or a replacement. 1. Switch the AUTO/MANUAL switch to MANUAL. Turn TENSION switch ON. The clutch should be connected across TB2-B1(+) and TB2-B2 (-). The voltage across the clutch should vary between 0VDC (+ .2VDC) to maximum as the MANUAL pot is adjusted from fully CCW to fully CW position. (Note: The OUTPUT pot R37 located on the D10 board must be fully CW) Maximum output: The maximum DC output is adjusted using pot R1 (located on the PS10 board). The maximum output voltage should be equal to the clutch coil rating. If required, ad-just R1 until the correct output level is present. This completes the troubleshooting for the PS10 and E10 board. Because these boards are so complex it is impossible to test each circuit and feature at this level of testing. If you have any questions as to the boards performance it may be wise to return it for repair or a replacement.
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