Tension
Control
Systems
WARNER ELECTRIC
WARNER ELECTRIC
2
WARNER ELECTRIC offers the most
complete product line dedicated to
the TENSION CONTROL MARKET.
The long experience in the market led
us to develop high performance controls
able to operate in open and closed loop
with brakes and motors.
WARNER
ELECTRIC electromagnetic brake find
an optimum use in tension control when
associated with the new digital control
line.
ABOUT THIS CATALOGUE
This master catalogue groups all
the solutions / products that
WARNER ELECTRIC offers. An
important part is dedicated to the
solution design with particular
consideration regarding the machine
and the tension control installed.
This should help you for the right
solution choice taking in considera-
tion the results you want to achieve.
All the product characteristics and
dimensions are included for every
product.
Tension Control Systems
Applying the appropriated
Tension Control will lead you
■ To save material
■ To improve quality of the
operation
■ To increase the production
■ Finally to lower your production
cost
ASK WARNER ELECTRIC
FOR ANY ASSISTANCE YOU
WOULD NEED
3
❐ Tension control definition
❐ Tension control applied
❐ Tension control in open loop
❐ Tension control in closed loop
❐ Torque and power determination
❐ Configuration selection
❐ Closed loop – sensor selection
❐ Open loop – setting selection
❐ Tension brake overview
❐ Tension brake sizing
❐ Tension brake for strapping
machine
❐ TB brake selection/characteristics
❐ For electromagnetic brakes
❐ Closed loop control overview
❐ MCS202-E line
❐ MCS2000 line configuration
❐ MCS2000 line characteristics
❐ MCS2000-ECA
❐ MCS2000-CTDA/CTLC
❐ MCS2000-important features
❐ Open loop control MCS2000-CTOL
❐ MCS2000 control line dimensions
❐ Sensors overview
❐ End shaft load cell type ES
❐ Foot mounted load cell type FM
❐ Rotary sensors
❐ Linear sensor
❐ MCS2000 line - accessories
❐ Rotary sensors - accessories
❐ All sensors/accessories dimensions
Index
MARKET / SOLUTION
WARNER BRAKE RANGES
DRIVERS
CONTROLS
SENSORS / ACCESSORIES
22
134
21
14
33
23
40
34
4
Before going through the various products and solutions WARNER ELECTRIC can
offer, it is important to make a correct analysis of the need. What we call “need” is the
tension control accuracy you need to operate a good material transfer through the
machine and realize perfect operation on the material.
MARKET /
SOLUTION
Tension control definition
WHAT’S TENSION CONTROL ?
The tension control is the ability to permanently control the
mechanical tension in any material (mainly the raw material
available in roll size). This control has to be operated dynam-
ically and statically. On every machine the operator should
be only concerned by the speed and operation. The line
speed is considered as master function. The tension control
must be efficient at any machine speed phase, including
machine acceleration, steady and speed deceleration.
Emergency stop case does not require accurate tension
control but should act in the way to avoid the web breakage.
It is then very important to consider all machine speed
phases for the system determination.
WHY A TENSION CONTROL ?
When web material has to be treated in a specific machine
(printer, slitter, coater….) it is very important to transport the
web with a controlled tension for two main reasons :
❐
Correct web transport in the machine
❐
Correct operation on the transported material
On the other hand, this kind of machine works very often
with an “edge guiding system”. Loosing the tension in
material will affect the correct edge guiding system.
WHERE DOES IT APPLY ?
In any roll fed web processing machine. Typically :
❐
PRINTING machine
❐
LAMINATING machine
❐
SLITTING machine
❐
SHEETING machine
❐
COATING machine
❐
EXTRUDERS
❐
Stand alone UNWINDER / REWINDER
❐
In general all CONVERTING equipment
Treating material such as:
❐
Paper
❐
Plastic film
❐
Textile
❐
Aluminium foil
❐
Wires / cables
In general in all machines whose block diagram can be
represented as follows:
5
Analysing and preparing a project in tension control requires good analysis support.
The general block diagram below is a good representation of any machine generally
supporting tension control. We recommend to use this diagram or a part of it in any
discussion and correspondence in order to be clear and to avoid possible misunder-
standings.
MARKET /
SOLUTION
Tension control application
A
D
B
C
X
Y
Z
Zone 1
Zone 2
Zone 3
IMPORTANT CONSIDERATION
In every machine the speed point location must be clearly identified. In general one of the machine nip roll is driven setting
the linear velocity of the machine. The machine speed is considered as
MASTER function. The tension control, whatever
the choosen solution, works in
SLAVE mode. Practically, the operator sets the machine speed with a simple potentiometer
and all tension control system existing on the machine have to follow, keeping the desired tension at any speed and during
all transitory speed phases.
REFERING TO THE GENERAL BLOCK DIAGRAM
Three zones are clearly identified :
ZONE 1, Typical characteristics
(unwind)
❐ Tension zone definition : A-B
❐ Speed point in B
❐ Variable roll rotation speed
❐ Variable inertia
❐ In general constant tension X
❐ Brake system applicable
❐ Motor system applicable
Zone 3, Typical characteristics
(rewind)
❐ Tension zone definition C-D
❐ Speed point in C
❐ Variable roll rotation speed
❐ Variable inertia
❐ Constant or Taper tension Z
❐ Brake not applicable
❐ Motor system required
ZONE 2, Typical characteristics
❐ Tension zone definition B-C
❐ Speed point in B or C
❐ Constant roll rotation speed
❐ Constant inertia
❐ In general constant tension Y
❐ Brake system applicable
❐ Motor system applicable
NOTE : Each zone is individually controlled. Tension may be different in each zone. It is assumed that there is no slipping on the nip roll.
GENERAL BLOCK DIAGRAM
6
Working in open loop requires an external reference setting applied to the driver. The
torque applied to the unwind roll has to vary according to the diameter of the roll.
Open loop solution is generally a low cost solution but with limited accuracy.
MARKET /
SOLUTION
Tension control in open loop
OPEN LOOP SOLUTION
The open loop configuration does not require any control or sensor. It is composed only with a power element (brake or
motor) and an associated driver. In this case the torque is
not controlled. We have
to set the torque on the driver accord-
ing to the diameter of the roll. The electrical block schematic drawn from the closed loop system becomes as follows:
The power part is transmitting the necessary torque to the
roll. Since the result is not measured, all the effect due to
the inertia of the roll influence the tension in the web. Some
compensations are possible but the system stays an open
loop with limited accuracy.
Torque setting
Driver
Power
THREE POSSIBILITIES TO APPLY THE SETTING
❐
MANUAL by
potentiometer
❐
AUTOMATIC with the
diameter reading
❐
AUTOMATIC with the
diameter calculation
Driver
Driver
Driver
Diam
Calculator
T
T
To summarize, the web tension control can be operated in two system configurations
OPEN and
CLOSED loop. For each
configuration, three main possibilities for SETTING respectively SENSING are possible. The solution choice depends on :
❐
First the accuracy you need in your web tension
❐
The mechanical construction of the machine
❐
The degree of automation you need
❐
The acceleration/deceleration imposed on the system
In the next section
WARNER ELECTRIC gives you some criteria to facilitate your choice. It’s not our intention to impose a
solution but just to offer a guide drawn from the
WARNER ELECTRIC experience. We put the accent on the limit of
various possibilities in order to start your project on a healthy base and really get the result you are expecting.
The diameter calculation is based on line and rotation speed
information.
This solution requires to have both information available.
7
To create a tension it is necessary to apply a force or more precisely a torque when
applied to a turning part. WARNER ELECTRIC is manufacturing a wide range of
brakes from fractionnal Nm to thousands of Nm. Two main solutions exist in terms of
system configuration to apply the right torque:
❐
Closed loop control.
❐
Open loop control (or more precisely open loop setting).
MARKET /
SOLUTION
Tension control in closed loop
CLOSED LOOP SOLUTION
The tension control, as any electronic control, is working basically in closed loop according the electrical block diagram
below. In closed loop
we sense the result we want to achieve and compare it with a reference in order to ensure
permanent balance between what we want and what we have.
Reported as example of an unwind stand
The closed loop is an electrical/mechanical loop.
It’s easy to understand that in such a loop all parts
are important in terms of quality.
❐ The control – has to have high performance to
manage all parameter changes correctly during
the operation.
❐ The driver – has to be as fast as possible in
terms of response.
❐ The power part – has to be sized correctly
according to the need and as fast as possible
in terms of response.
❐ The sensor – has to be accurate, stable over
time and to have a good repeatability.
The quality of the mechanical construction is important. The control loop is closed through the mechanical transmission
between the power element and the sensor roll. The web itself is a part of the loop. In the case of webs with high
elasticity, special consideration should be given in control setting.
THREE WAYS TO SENSE THE TENSION
Control
Driver
Power
Sensor
Reference
(What we
want)
Feedback (What we have)
(Brake or Motor)
The closed loop
Sensor
Power
Driver
Control
Reference
❐
Direct tension measure-
ment with
LOAD CELL.
❐
Indirect tension measure-
ment with
DANCER ARM.
❐
Indirect tension measure-
ment with
FREE LOOP.
8
Let’s take, as an example, a complete slitter-rewinder machine in order to establish a
complete “power balance” sheet about the torque. The power we need in the three
machine zones is the following:
❐
Unwind part (zone 1)
❐
Machine process part (zone 2)
❐
Rewind part (zone 3)
MARKET /
SOLUTION
Torque and power determination
“POWER” FROM MOTOR OR BRAKE ?
Based on two parameters :
❐ Do I need a positive torque or is a negative torque sufficient ?
❐ Which technology is on the machine ?
In the case where the “torque need” calculation shows positive results we
are forced to use a motor. Only a motor is able to provide positive torque.
It’s typically the case on the rewind stand. On the other hand, for the unwind
stand the brake solution very often suits the requirements.
The technology parameter is purely a customer decision. The tension
control with motor is today operated with AC motor and flux vector control
drive with full power regeneration in the line.
WARNER ELECTRIC offer both solutions with a wide range of products.
TORQUE NEED EVALUATION
Example of calculation on a typical machine (slitter / rewinder).
Unwind stand (zone 1)
X
Y
1
2
3
3
Slitter
Unwind
stand
Rewind
stands
Parameters given
Unwind tension zone X
250 N
Rewind tension zone Y
100 N, all rolls
Taper tension zone Y
40%
Max unwind roll diam.
1 m
Max rewind roll diam.
0,5 m
Min unwind roll diam.
0,09 m
Min rewind roll diam.
0,06 m
Max line speed
400 (m/min)
Accel
50 m / min / sec
Decel
150 m / min / sec
Max unwind roll weight
500 Kg
Max rewind roll weight
80 Kg, all rolls
The torque need for each machine phase shows a negative result. Brake and motor can comply with all parameters.
Whatever the choice the selection must be based on the max requirements of heat, torque and speed.
Max torque to provide the tension
- 1 m * 250 N / 2
-125 Nm
Min torque to provide the tension
-0,09 m * 250 N / 2
-11,25 Nm
Inertia of the full roll
0,5 * 500 Kg * 0,5 m * 0,5 m
62,5 Kgm2
Max rotation speed (at full line speed)
+ (400 m/min / 0,09m / 3.14)
+1415 rpm
Min rotation speed (at full line speed)
+ (400 m/min / 1m / 3,14)
+127 rpm
Torque to accelerate the full roll
+ (62,5 Kgm2 * 127 rpm / 9,55 / 8 sec)
+104 Nm
Torque to decelerate the full roll
- (62,5 Kgm2 * 127 rpm / 9,55 / 2,66 sec
- 312 Nm
Torque need on the roll to insure correct tension
- In acceleration
- 125 Nm + 104 Nm
-21 Nm
- During steady speed for D to d
-125 Nm to -11,25 Nm
-125 to -11,25 Nm
- In deceleration
-125 Nm - 312 Nm
-437 Nm
- Max continuous power dissipated
- 125 Nm * 127 rpm / 9550
-1,66 kW
250 N
100 N
100 N
9
MARKET /
SOLUTION
Torque and power determination
Rewind stand (zone 3)
Both shafts are similar in terms of mechanical parameters. It’s practically always the case for slitting machines.
MAIN DRIVE NIP ROLL (zone 2)
MACHINE POWER BALANCE
Unwind stand
– 1,66 kW
Main drive
+ 0,87 kW
Rewind shaft (2)
+ 0,80 kW
TOTAL POWER
+ 0,01 kW
(due rounded number)
0,00 kW
Please note it is a theoretical calculation. We did not take all the initial
friction account. Looking at the torque need for each zone we can say:
❐ Tension function on unwind stand can be achieved by motor or brake.
❐ Nip roll system has to be motor driven.
❐ Tension function on rewind shaft must be provided by motor.
WARNER ELECTRIC can offer you the appropriate solution whatever your choice:
wide range of electrical brakes as well as motorised solutions.
Please see pages 14 to 19 for component selection.
Max torque to ensure the tension (biggest diameter, all rolls)
+(0,5 m * 100N * 60% / 2)
+15 Nm
Max torque to ensure the tension (smallest diameter, all rolls)
+(0,06 m * 100N / 2)
+3 Nm
Max shaft rotation speed
+(400 m/min / 0,06 m / 3,14)
+2123 rpm
- In reality the max speed in never reached on the core diameter.
For the max speed on the core we can assume a practical reduction of 25%
Then max rotation speed
+(2123 rpm * 75%)
+1592 rpm
Min shaft rotation speed
+(400 m/min / 0,5 m / 3,14)
+255 rpm
- In reality the full roll is never reached at full speed
For the min speed at full roll we can assume a practical reduction of 25%
Then min rotation speed
+(255 rpm * 75%)
+ 191 rpm
Inertia of the full roll, all rolls
0,5 * 80 Kg * 0,25 m * 0,25 m
2,5 Kgm2
Torque to accelerate the full roll, all rolls
+(2,5 Kgm2 * 191 rpm / 9,55 / 8 sec)
+ 6,25 Nm
Torque to decelerate the full roll, all rolls
–(2,5 Kgm2 * 191 rpm / 9,55 / 2,66 sec) – 18,8 Nm
Final torque need on the roll to ensure correct tension
- In acceleration
+ 15 Nm + 6,25 Nm
+ 21,25 Nm
- In steady speed for d to D
+ 3 to + 15 Nm
+ 15 Nm
- In deceleration
+ 15 Nm – 18,8 Nm
– 3,8 Nm
- Max power continuous dissipated per shaft
+ 15 Nm * 255 rpm / 9550
+ 0,4 kW
Necessary theoretical power :
Worst tension balance = 250 N – (2 * 100 N * 60%) = 130 N
Max power need = 130 N * 400 m/min/60 = 867 W
Max roll rotation speed : depends of nip roll diameter
10
The power part selection is the same whatever the configuration. As soon as the
power element and its associated drive are defined we have to determine how the
system will be driven: in open or closed loop ?
As previously stated, one important factor is the tension accuracy you need.
MARKET /
SOLUTION
Configuration - selection
CLOSED LOOP - ADVANTAGE / DISADVANTAGE
OPEN LOOP - ADVANTAGE / DISADVANTAGE
DO NOT FORGET : all above considerations - even if example is unwind stand - are applicable to the three
various machine zones we have defined on page 5.
Every zone of the complete machine can be controlled with its own appropriate tension system configuration. A typical
example is the tension in a printing machine. It is very often controlled on an unwind stand in closed loop where the
accuracy is important for good printing and on a rewind stand in open loop where the tension precision is not so important
after the print operation.
Finally it’s the customer decision.
WARNER ELECTRIC can offer advise in solution and product choice.
Advantage
❐ High accuracy.
❐ All initial friction in mechanical parts, even if they
are changing over time are overcome.
❐ Tension is controlled during all the machine
speed phase (accel, decel, steady speed).
❐ System can work in slave without any electrical
connections to the machine.
Disadvantage
❐ Risk of instability.
❐ Can be more complex to set-up.
❐ More expensive compared to open loop.
Advantage
❐ Very stable.
❐ Easy to start-up.
❐ Low cost compared to closed loop (sensor and
control units not required).
Disadvantage
❐ Poor accuracy
❐ Strongly dependent on quality of mechanical parts.
❐ Accel, decel phase reflected on tension.
Feedback
Sensor
Power
Driver
Control
Reference
Machine
with speed
imposed by
operator
Power
Driver
Machine
with speed
imposed by
operator
Setting :
❐ Manual
❐ Diam. measure
❐ Diam. computing
Type of sensor
Where, When, Why ?
Advantage
Disadvantage
Load cell
❐ Slitter, Sheeter, Coater
Direct tension measure
No tension peak absorption
❐ For heavy material
Mechanically well integrated Accel/decel machine not
❐ Limited room
No moving part
easy to manage
❐ No fast accel/decel
Flying splice function
❐ Tension peak accepted
not easy
Dancer arm
❐ Printing
Absorb tension peak
Need more space
❐ Intermittent function
Can act as store
Moving parts
❐ Flying splice need
Easy flying splice
Accel / decel machine
phase well absorbed
Flexibility
Free loop
❐ Textile machine
Same as Dancer arm
Same as dancer arm
❐ Very low tension
Reliable position reading
not easy
11
If your machine requires a very accurate web tension control, then you need to work
in closed loop. An important unit in the loop is the sensor. Three main possibilities are
offered. The choice is now depending on the kind of machine you are building, the
mechanical construction and the max tension value you desire to control.
WARNER ELECTRIC bring you their experience for selection according various criteria.
MARKET /
SOLUTION
Closed loop - Sensor selection
MAIN APPLICATIONS - ADVANTAGE - DISADVANTAGE FOR THE THREE POSSIBILITIES
LOAD CELLS SIZING - MOUNTING RECOMMENDATIONS
Please keep this principle in mind:
The load cell installed is destined to measure the
WEB TENSION and not other constraints applied to it.
Wraping
angle
❐ In any cases the machine speed profile is important. The accel/decel machine ramps have to be electrically managed.
❐ In any mechanical construction (dancer arm), all the inertia has to be minimized.
Take the following points into consideration before selecting, sizing and installing material components.
❐ Load cells location should be vibration free. Vibrations will decrease quality measurement.
❐ The sensing shaft fitted on or in has to be very well balanced. Unbalanced shaft will create measurement oscillation,
causing variations in control quality.
❐ Adapted ball bearing have to be used to avoid original stress on load cell ( self-aligning ball bearing).
❐ Respect a reasonnable sensing shaft weight/web tension measure ratio.
Less than 1.
❐ Do not oversize the load cell respect to your calculation.
Max admitted factor 3, recommended 1,5.
❐ Respect a minimum wrapping angle on load cell.
Min = 240°.
❐ So far as it is possible, use load cell in compression, with web tension effect in same direction as the weight of shaft.
12
MARKET /
SOLUTION
Closed loop - Sensor selection
DANCER ARM BUILDING AND OPERATIONAL
RECOMMENDATIONS
Dancer arm system is used for indirect tension measurement. It is in fact a
position control. The desired tension in web is provided with an external
component. As general principle keep this concept in mind :
We have to create tension with force and not with a weight.
Take the following points into consideration before manufacturing, sizing and installing the components.
❐ Moving part of dancer has to be as light as possible.
❐ The dancer can act as both position control and web accumulator.
❐ The larger the quantity of material stored in dancer, the easier will be the position control, and hence the tension control.
❐ To set tension you need to use a pneumatic actuator “P” acting on arm of the swinging roll.
❐ In case of light tension do not add balance weights to compensate for excessively heavy dancer arms, but choose free loop.
FREE LOOP INSTALLING RECOMMENDATIONS
This is an indirect tension measure. It is in fact a position control similar to
the dancer arm. The loop position is read with ultrasonic sensor. Free loop
is applied especially in textile market where tension required are generally
low. The free loop system suits to the requirement expressed as “zero
tension”. Main difficulty is to obtain reliable position reading.
For free loop operation the following points should be taken into consideration:
❐ The tension in material is the own weight of material in the loop.
❐ A light core “C” often is placed in the loop to immobilise the loop, making easier the position reading.
❐ As the system is very light it is very sensible to the “wind”. Some guards “G” are installed to prevent accidental loop moving.
❐ As the system is dedicated to very low tension it often requires a motor as power system.
T
T
P
W
C
G
13
Working in open loop requires that a torque setting is defined. As seen on page 7,
three possibilities exist. The choice depends on the machine complexity and the
automation required. One important factor that remains is the tension precision. For
unwind and rewind systems the diameter ratio will play an important role. Working in
open loop also requires special considerations regarding system inertia.
MARKET /
SOLUTION
Open loop - Setting selection
Setting type
Where, When, Why ?
Advantage
Disadvantage
Manual setting by pot.
❐ Cable machine
❐ Low cost solution
❐ Tension precision
❐ No fast accel/deccel
❐ Easy to start-up
depends on operation
❐ Low roll diameter ratio
❐ Operator intervention
admitted
Diameter reading
❐ The most commonly used ❐ Physical reading,
❐ Poor reading accuracy
solution in open loop
no reset
on core
❐ No operator
❐ Easy to start-up
intervention admitted
❐ Large roll diam ratio
Diameter computing
❐ In rewind station
❐ Electrically integrated
❐ Need line speed signal
❐ In sophisticated
❐ Easy compensation
❐ Need roll rotation
machine
for transitory phases
speed signal
❐ Large roll diam ratio
❐ Can be complex to
set-up
❐ Need reset
MAIN APPLICATIONS - ADVANTAGE - DISADVANTAGE FOR THE THREE POSSIBILITIES
❐ All solutions remain an open loop solution with limited precision.
❐ As we do not measure the result we want to achieve, all initial friction and inertia influence the precision of the system.
SOME PRECAUTIONS WHEN USING READING SOLUTION
Reading solution is generally with
ultrasonic sensor. Another type of reading is
the roll arm
follower. Both use the same principle. The roll diameter measure is applied as torque
setting on the power part driver. The sonic reading offers the advantage of not touching the
roll. The reading reliability is the weak point of the system. Ultrasonic sensor location is
important and should respect the recommendations below.
The block diagram used in all ultrasonic open loop application shows the sonic in
any position. The position shown in explanation is not necessarily the ideal
position to get good reading reliability. The problem when using sonic reading is
to get signal reliability at the end of the roll when approaching the core. The best
position when applicable is the position shown on this diagram where the sensor
position axis is voluntarily offset from the theoritical vertical axis. Placing the sen-
sor axis in X position will ensure a good and stable reading even at the end of the
roll. The small error provided is not important and the reading stability is
guaranteed.
X
14
The selection of the power part element (brake or motor) is determined by the max
torque needed to ensure the tension for the max machine speed. The basic principle
is to calculate the torque we need to obtain the desired max tension needed during
all machine speed phases (see complete example on pages 8-9).
TENSION BRAKE
LINE
Tension brake overview
WARNER ELECTRIC BRAKE RANGE
Analysing the following considerations will lead you to
select the right brake for your application :
❐ The max calculated torque you need.
❐ The modularity needed.
❐ The mechanical size (square or round size, dimensions).
NOTE: The sizing of brake or motor is absolutely indepen-
dent of the control system you have chosen (open or closed
loop).
16 17
WHICH TYPE FOR WHICH APPLICATION ?
18 21
BRAKE TYPE
MAIN CHARACTERISTICS
TORQUE RANGE
TBM SIZE 10
❐ Electromagnetic brake
10 Nm
❐ Monodisc
❐ 24 VDC power supply
❐ 1 size
TB
❐ Electromagnetic brake
❐ 0,5 Nm to 300 Nm
❐ Monodisc
❐ 24 VDC power supply
❐ 8 sizes
TB brake selection is based on two values :
Max torque need (Nm) on the brake
*Max brake rotation speed for the max torque (rpm)
* As the curve given for TB selection takes the power dissipation into account, this value is used.
15
Two important parameters are used in brake selecting:
❐
Max torque requirement
❐
Max thermal power to be dissipated
These two values are determined by the application (see calculation example
on pages 8-9).
TENSION BRAKE
LINE
Tension brake sizing
ELECTROMAGNETIC BRAKE TYPE TB - SELECTION
Tmax = max torque needed at the brake for the
max tension in material and the max roll
diameter - taking any gear ratios into account.
Nmax = max brake rotation speed for the max
linear speed and the max roll diameter – taking
any gear ratios into account.
Gear box
Brake
Speed
Torque
See complete selection curves page 18.
Selection point
Tmax
Nmax
Note : the constant tension in the web gives a
constant power on the brake. However, we
make the selection for the max torque (then at
full roll diameter) because it’s the moment
where the brake has the least natural cooling.
Specially designed for strapping machine, the electromagnetic brake TBM10 is
adjustable for the different kind of plastic film. Mounted on the intermediate roller, it
will tighten the plastic film and will permit a perfect strapping.
TENSION BRAKE
LINE
Tension brake for strapping machine
n (min )-1
M (Nm)
d
20
15
10
8
6
5
4
3
0
100
200
300
500
400
Brake torque
8
6
4
3
2
1.5
1
M (Nm)
n (min )-1
d
10
15
20
40 60
80
150
300 500
200
100
400
30
50
Heat dissipation curve
TBM SIZE 10
PALLET
PLASTIC FILM ROLLER
TBM BRAKE
16
TENSION BRAKE
LINE
Tension brake for strapping machine
TBM SIZE 10
U max : 24 VDC - P 20°C = 10,8 Watts
Part
TBM SIZE 10
1
Inductor 24VDC
B6650-631-000-39
2
Armature VAR 03
B110-0000-1358
3
Hub prebored ?7,5
B540-0000-2519
Hub ?12 H8 + Keyway 4 P9
B540-0000-2517
4
Armature VAR 04
B6650-111-000-08
17
4.5
h9
300
T
45°
?
90
D max = 13 mm with standard keyway
D min = 8 mm with standard keyway
26
?
5.5
?
100
?
81
D H8
VAR 03
?
42
P9
➂
➁
➀
T
7.9 H8
8.3
3 pins on ? 57.96
?
41
VAR 04
26
? 0,10
➀
➃
Keway according to : ISO R773 / BS 4235 /
NFE 22175 / tolerance P9
18
The table (pictured below left) illustrates the selection of the correct TB brake. The
right table determines the maximum torque provided by the brake when nominal
voltage is applied. After selection you can consult the complete brake characteristics
and dimensions on pages 18 to 21.
TENSION BRAKE
LINE
TB Brake selection
400
300
200
150
100
80
60
40
30
20
15
10
8
6
4
3
2
1,5
1
0,8
0,6
0,4
0,3
0,2
10
15
20
30
40
50
60
80
100
150
200
300
400
500
TB 825
TB 1000
TB 500
TB 425
TB 260
TB 170
TB 1525
TB1225
To
rque
M
d
[Nm]
Brake
n [rpm]
200
500
400
300
200
150
100
80
60
50
40
30
20
15
10
8
6
5
4
3
2
1
0,8
0,6
0
100
300
400
500
TB 1525
TB 1225
TB 1000
TB 825
TB 500
TB 425
TB 260
TB 170
Brake torque
M
B
[Nm]
Brake
n [rpm]
Dynamic brake selection TB170 - TB1525
Static brake torque TB170 - TB1525
19
TB units are assembled using various parts described below. Main components of the
brake are armature and magnet. Additional parts are offered to provide for ease of
mounting.
TENSION BRAKE
LINE
TB Brake characteristics
* Prebored
** Indicate bore and keyway
Part
TB170
TB260
TB425
D = 46 mm
D = 69 mm
D = 111 mm
1
Armature hub*
B5102-541-001-38
B5103-541-001-47
B5104-541-001-31
2
Armature
K110-0096
K110-0097
K110-0098
3
Magnet 24V
K375-631-012
K5365-631-016
K5367-631-008
R = 110 Ω, 20°C
R = 60 Ω, 20°C
R = 76 Ω, 20°C
4
Terminals
Wires
B5103-101-002
B5103-101-002
Part
TB825
TB1000
TB1225
TB1525
D = 215 mm
D = 259 mm
D = 316 mm
D = 395 mm
1
Taperlock bushing**
B180-xxxx-xxxx
B180-xxxx-xxxx
B180-xxxx-xxxx
B180-xxxx-xxxx
2
Armature hub
B540-0394
B540-0313
B540-0015
B540-0314
3
Armature
B5301-111-019
B5302-111-021
B5303-111-011
B5304-111-005-04
4
Drive pins
B5301-101-001
B5301-101-001
B5301-101-001
B5301-101-001
3 x
3 x
4 x
4 x
4
Magnet IM 24V
B5311-631-000-30
B5312-631-000-36
B5313-631-000-11
B5314-631-000-08
R = 20 Ω, 20°C
R = 20 Ω, 20°C
R = 22 Ω, 20°C
R = 20 Ω, 20°C
5-1 Terminals
B5311-101-001
B5311-101-001
B5311-101-001
B5311-101-001
6
Magnet OM 24V
B5311-631-000-16
-
-
-
7
Conduit box
K5200-101-011
K5200-101-011
K5200-101-011
K5200-101-011
Part
TB500
D = 130 mm
1
Taperlock bushing** B180-xxxx-xxxx
2
Armature hub
K5300-541-004
3
Armature
B110-0047
4
Drive pins
K5300-101-003
3 x
5
Magnet IM 24V
B5300-631-040
5-1 Terminals
B5311-101-001
6
Magnet OM 24V
B5300-631-000-46
7
Conduit box
K5200-101-010
20
The table below shows all characteristics and dimensions. All TB brakes are rated at
24 VDC nominal. When selection is correct the voltage on the brake should be
approximatively 12 VDC for your maximum parameters used in calculation.
All TB brakes are able to work for short periods of time (less than 10 seconds) in
the 12-24 VDC range, for example in machine deceleration.
TENSION BRAKE
LINE
TB Brake characteristics
TECHNICAL DATA AND DIMENSIONS
Size
TB170
TB260
TB425
TB500
TB825
TB1000
TB1225
TB1525
Md
[Nm]
0,8
4
16,5
35
75
150
300
450
Md min
[Nm]
0
0,08
0,16
0,2
0,5
1,1
2
3
n max
[rpm]
5000
5000
5000
5000
3000
2400
2000
1600
I 24V =
[A]
0,22
0,40
0,32
1,010
1,177
1,224
1,076
1,212
R 20° C
[Ω]
110
60
76
23,8
20,4
19,6
22,3
19,8
tb
[s]
0,020
0,040
0,080
0,052
0,112
0,152
0,290
0,310
Inertia
[kgm2]
12 • 10-6
116 • 10-6
1,4 • 10-3
1,9 • 10-3
0,022
0,041
0,095
0,213
Mass
[kg]
0,180
0,650
1,800
2,3
8,2
12
21
27,5
A
30,5
48,5
52
79
94
105
138
116
B
7
12
14
77
30,5
30,5
30,5
30,5
C
-
-
-
51
54
56,5
62
65
?D
46
69
111
130
215
259
316
395
E
20,6
32
30,5
30,5
33,5
36,5
41,5
44,5
?
H
?
D
?
S
?
L
A
E
0,4
K
B
?
G
?
Q
B
?
D
?
H
?
M
?
L
?
N
?
S
?
G
?
Q
?
P
A
C
E
3,2
2,4
K
?
D
?
N
?
S
?
Q
?
P
?
M
?
G
?
L
C
A
B
T
K
F
3,0
3,2
1,2
E
1,6
?
9,52
±0,0
25
TB170, TB260, TB425
TB500 IM
TB500 OM
TB825 IM, TB1000 IM, TB1225 IM
TB825 OM, TB1000 OM, TB1225 OM
21
* Reverse mounting of taperlock bushing is possible
B
2,4
K
3,5
E
C
A
?
D
?
M
?
H
?
L
?
G
?
N
?
P
Non magnetic
Steel
< 0,2 % C
?
U
10
15
661-0005
?
12,7
+0.01
-0
30
9,5
M
1/2 -13 U
N
C-3B
?
12,7
+0.025 0
TB1525 IM
TB825 - 1525
Dimension details complementary to page 20.
TENSION BRAKE
LINE
TB Brake characteristics
Size
TB170
TB260
TB425
TB500
TB825
TB1000
TB1225
TB1525
F
-
-
-
28,5
-
-
-
-
?G
19,5+0,05
35
62
49
55
98
114
180
?H
15,9
30,1
31,8
-
118
159
175
152,5
K*
10,3
17,5
22,2
38
38
44,5
76
76
?L max
10
20
22
32
42
60
75
75
?M±0,025
-
-
-
98,42
90,49
133,4
149,3
215,9
3 × 120°
3 × 120°
3 × 120°
4 × 90°
4× 90°
?N±0,05
-
-
-
52,40
88,93
136,55
161,95
228,60
?P
-
-
-
60,3
108
155,6
184,1
247,60
-
-
-
8 × M4
6 × M8
6 × M8
6 × M8
12 × M8
?Q-0,05
61,9
88,9
142,47
165,10
247,62
-
-
-
54
79,4
127
149,2
255,5
-
-
-
?S
4 × M4
4 × M4
4 × M6
4 × M10
4 × M8
-
-
-
T
-
-
-
49
-
-
-
-
?U
-
-
-
110
170
220
260
340
Considering the power element, we need to “drive” this with a DRIVER. The driver is the
element providing the necessary power to the “power element”. The driver can be
considered as power interface between CONTROL and POWER ELEMENT. The
driver has to be “power” compatible with the power element (electrical brake or motor)
and the “signal” compatible with the control or the setting.
DRIVERS
For electromagnetic brakes
ELECTRICAL DRIVER
All the TB type electrical brakes are rated for 24 VDC.
The highest current consumption is 1,24 A for the model TB 1525.
Three models are available to drive our TB brakes and all models are dual channels (two individual channels in same
housing). Input and output characteristics shown below are per channel.
22
Model
Electrical
Power supply /
Output voltage /
input signal
current
current
MCS2000-DRV
0 – 10 VDC
24 VDC/3 A
0-24 VDC/1.4 A
MCS2000-PSDRV
0 – 10 VDC
100 – 280 VAC
0-24 VDC/1.4 A
MCS2000-DRVH
0 – 10 VDC
48 VDC/12 A
0-48 VDC/6 A /12 A
0 – 20 mA
peak 30 sec
MCS2000-DRV8
0 – 10 VDC
24 VDC/3 A
0-24 VDC/3 A
Wiring
Input signal shielded
Setting
Anti-residual
Mounting position
Vibrations free, vertically
Most tension controls work in closed loop configuration. In this case the CONTROLLER
is indispensable. This element is the heart of the system. The control is continuously
comparing the web tension information coming from the SENSOR with the tension
reference we give to the controller. As soon as the controller detects a difference
between the two values a correction is applied to the power element through the driver.
CONTROLS
Closed loop control overview
WARNER ELECTRIC CONTROL LINE OVERVIEW
Low cost analogue control
including driver
in 3 versions:
❐
MCS202-E1
standard version.
❐
MCS2000-E54
IP54 protected.
❐
MCS202-EC1
Open frame standard
version.
Digital control in 3 versions:
❐
MCS2000-ECA
OEM version.
❐
MCS2000-CTDA user version for dancer
application.
❐
MCS2000-CTLC
user version for load cell
application.
Control
Driver
Power
Sensor
Reference
Feedback
MCS202-E
Reference
Feedback
MCS2000
Reference
Feedback
23
The MCS202-E is an analogue control. It is dedicated to electromagnetic brakes and
accepts only dancer as feedback. The control is not provided with internal logic
function for splice. It suits the simple application and is very easy to start-up. All
connections are made by connector avoiding the wiring error risk. Warner can supply
the sensor and other accessories for easy mounting.
CONTROLS
MCS202-E line
ANALOGUE CONTROL MCS202-E
Dimensions
37
29
99
51,5
73
282
265
60
87
120
57
?
65
14,3
POWER
BRAKE
LOOP GAIN
TORQUE OFFSET
MCS 202-E
Range - Values
Comments
Power supply
110-220 VAC selectable
Open front face to acceed
Output current capability
Max 2, 5 Amps, shortcircuit protected
Able to power 2 TB in parrallel
User settings
Loop gain
Front face potentiometer
Offset torque
Front face potentiometer
Output voltage
0-24 VDC
Compatible all elec. Warner brakes
Housing
Metal rugged housing
Only MCS202-E1 and –E54
Loop gain
2 adjustable range selection
Can be change during operation
Accessories
MCS-KIT1, 2, 3, 5 and 6
See details on page 40
Sensor compatible
Dancer arm with MCS605-E
See details on pages 37 and 40
Technical Characteristics – valid for 3 executions
Technical information
MCS202 control is based on
classical and fixed PID terms.
The loop gain can be set on
front face potentiometer. Due
to the fixed PID terms, its use is
limited in terms of roll diameter
ratio. One input is provided to
change the loop gain and has
to be used when diameter ratio
exceeds 8 to 10. To ensure
proper operation it is important
to wire the function “Drift Stop”.
This function releases the
Integral term as soon as the
machine runs.
TB Brake
Control
Sensor
❐
MCS202-E1
Standard execution.
❐
MCS202-E54
Standard IP54 protected.
❐
MCS202-EC1
Open frame execution.
24
MCS2000 is a product line developed around the controller MCS2000-ECA.
MCS2000-ECA is the heart of the complete configuration grouping Driver, Power
supply, Programming tool, Display, Interface sensor…
The configuration is represented in the diagram below.
CONTROLS
MCS2000 line configuration
MCS2000 LINE CONFIGURATION
MCS2000-DRV8
Eight channel brake amplifier
22
MCS2000-ECA
Digital programmable controller - dual channel output.
28
MCS2000-PS
24 VDC power supply - 100-260 VAC auto-ranging input.
39
MCS2000-DRV
Dual channel brake amplifier with individual “anti-residual” adjustment.
22
MCS2000-DRVH
Dual channel brake amplifier with high output current capability.
22
MCS2000-PSDRV
Dual amplifier MCS2000-DRV and power supply MCS2000-PS in common housing.
22
MCS2000- PRG
Portable programming tool with 2 lines 16 character display.
39
MCS2000- DP
Panel mounted programming keyboard and display.
39
MCS2000-CRD
Plugable memory card with 2 full programme capacity.
39
MCS2000-IS
Ultrasonic and dual load cell interface.
39
MCS2000-WIN
Window software to interface the control to the PC (3 disks).
39
MCS2000-PLC
Codes list for PLC (terminal mode) - RS232 controller communication.
39
2 electro-magnetic
brakes 1,4A / channel
2 electro-magnetic brakes
3A / channel
8 electro-magnetic brakes
0,3A / channel
MCS2000 DRV
MCS2000 DRVH
MCS2000-DRV8
MCS2000-CRD
MCS2000-ECA
MCS2000-PS
Ultrasonic
Load Cell
MCS2000-IS
MSC2000-PRG
MCS2000-WIN
MCS2000-DP
MCS2000-PLC
Sensor
Controller
Amplifier
Brakes/Motors
25
Based on the MCS2000-ECA controller Warner has developed two additional ver-
sions as a “User Version”. These two versions were obtained by grouping some exist-
ing functions in the modular configuration. These two versions make the installation and
wiring easier. The programming tool – separate on the ECA version – is fitted as stan-
dard. Finally, three digital control units are available in the WARNER ELECTRIC range:
CONTROLS
MCS2000 line - characteristics
MODELS
MAIN CHARACTERISTICS
UTILISATION
MCS2000-ECA
Open + Closed loop control
Multipurpose OEM
PID compensation
RS232
Memory card
24V power supply
See details on page 28
MCS2000-CTDA
MCS2000-ECA + PS + DP
Dedicated dancer
in same housing.
110-240VAC power supply
See details on page 29
MCS2000-CTLC
MCS2000-ECA + PS + DP + IS
Dedicated load cell
in same housing.
110-240VAC power supply
See details on page 29
Use the reference below to order
with various software :
MCS2000-ECA
Standard software with RS232
Multipurpose OEM
MCS2000-CTDA-10
Standard software with RS232
Dedicated dancer
MCS2000-CTDA-11
Taper position function
Dedicated dancer
Limited RS232
MCS2000-CTLC-10
Standard software with RS232
Dedicated load cell
MCS2000-CTLC-11
Taper tension function
Dedicated load cell
Limited RS232
26
The block diagram below shows all important features installed in the MCS2000
control line. It is very important to understand all the possible configurations that the
control can provide.
CONTROLS
MCS2000 line - characteristics
MCS2000 Block diagram
MCS2000 Features
Features / compatibility
ECA
CTDA-10
CTLC-10
CTDA-11
CTLC-11
Power supply 110 / 240 VAC
✔
✔
✔
✔
Power supply 24 VDC
✔
Dancer use, one sensor input
✔
✔
✔
Load cell use, 2 sensors input
✔
✔
RS232 communication
✔
✔
✔
✔
✔
Window software programing system
✔
✔
✔
Taper function
✔
✔
✔
✔
Splicing capability
✔
✔
✔
✔
✔
Sensor auto-scaling
✔
✔
✔
✔
✔
Memory card support
✔
✔
✔
✔
✔
PID, individual term setting/online correction
✔
✔
✔
✔
✔
Options, accessories,
PRG
(see details on pages 34 and 39)
DP
PS
CRD
CRD
CRD
CRD
CRD
Curve set
I
D
P
FS
1
Set point
1
k OL
Output
configuration
Outputs
+
+
+
Open loop
setting
Independent and
automatic PID term
Closed loop gain
change (Fast Stop)
Input sensor amplifier
(only CTLC model)
Two outputs to manage
the flying splice
Open + closed
loop function
Open loop
output
Open loop
gain change
Analog
input
Sensor
input
27
MCS2000-ECA is a digital controller that can be used in both open or closed loop.
Operation in open and closed loop is also possible. It is mainly destined for OEM
application. The programming tool is detachable. Sensor, sensor mounting kit, display
are available as options. The unit has to be powered with 24 VDC.
CONTROLS
MCS2000-ECA
Features
❐ Fully digital, scrolling menu program.
❐ Multipurpose application.
❐ RS232 communication.
❐ Window programming software.
❐ Two ouput channels.
❐ Automatic sensor scaling.
❐ Programmable output configuration.
❐ Output sensor information.
❐ External set point change.
❐ Automatic or imposed PID correction.
❐ All features requested for tension
control.
❐ Plugable memory card.
❐ Sensor rescaling without tool.
Specifications
Input power supply
24 VDC ± 5%, 0,2 A
Analogue inputs
Two analogue inputs
0-10 VDC
Sensor input
Min 4 VDC delta in ± VDC
Analogue outputs
Two controlled channels
± 10 VDC, 0-20 mA
Open loop signal
0-10 VDC
Digital inputs
Set point change +
active low
Set point change -
active low
Gain multiplier
active low
Open + closed loop activation
acive low
Output limitation
active low
ABC binary combination
active low
ABC inputs synchronisation
active low
Sensor polarity change
active low
Stop integral term
active low
Digital output
Sensor level indication
Two binary outputs, active low
Other outputs
Power supply sensor
± 15 VDC / 100 mA
Voltage reference
+ 10 VDC /10 mA
Options / accessories
Rotary and linear sensors
see page 34
Programming tool
see page 39
Programming tool and display
see page 39
Window software
see page 39
Terminal mode communication
see page 39
Memory card
see page 39
DRV
ECA
28
Sensor
MCS2000-CTDA and CTLC are packaged versions. Power supply, programming
keyboard and display are built in. In the CTLC version (load cell), two load cell
amplifiers are installed as standard.
For both MCS2000-CTDA and CTLC two software versions are available. See
specifications below.
CONTROLS
MCS2000-CTDA / CTLC
Common features of all versions
❐ Three mounting possibilities.
❐ Software password protected.
❐ Fully digital, scrolling menu program.
❐ Multipurpose application.
❐ RS232 communication.
❐ Two ouput channels.
❐ Automatic sensor scaling.
❐ Programmable output configuration.
❐ Output sensor information.
❐ External set point change.
❐ Automatic or imposed PID correction.
❐ All features requested for tension control.
❐ Plugable memory card.
Common specifications
Input power supply
110-240 VAC selectable
Analogue inputs
Two analogue inputs
0-10 VDC
Analogue outputs
Two controlled channels
± 10 VDC, 0-20 mA
Open loop signal
0-10 VDC
Digital inputs
Set point change +
active low
Set point change –
active low
Set point change ±
front face switch
Gain multiplier
active low
Output limitation
active low
ABC binary combination
active low
ABC inputs synchronisation active low
Stop integral form
active low
Digital outputs
Sensor level indication
Two binary outputs
Other outputs
Power supply sensor
± 15 VDC / 100 mA
± 5 VDC / 100 mA
Power supply
24 VDC
Voltage reference
+ 10 VDC / 10 mA
Options /accessories
Memory card
see page 39
Window soft
see page 39
Rotary and linear sensor
see page 34
CTLC
One or two
load cell
29
PSDRV
CONTROLS
MCS2000-CTDA / CTLC
Various models definitions – specifications – typical applications
X
Y
Load cells
Motor - driving part
Rewind roll
diameter info
CTLC-11
Slitting
operation
P
S
DRV
TB
30
Model
Characteristics
Applications
MCS2000-CTDA-10
RS232
Dancer feedback
One sensor input
One sensor input
MCS2000-CTDA-11
Taper position function
Dancer feedback
Limited RS232
RS232
MCS2000-CTLC-10
Two scalable sensor input
Load cell feedback
Two scalable sensor input
MCS2000-CTLC-11
Taper tension function
Load cell feedback
Limited RS232
Taper function
The most usual application requiring taper function is the rewind stand where the initial tension on the core has to be
automatically reduced as the diameter increases. Rewind diameter information / feedback is essential. The typical
application is slitter where no intermediate driving roll is present. The unwind tension, in this case, is the same as rewind
and has to be tapered. The tension is identical in zone X and Y.
The tension reference on the controller MCS2000-CTLC-11 is continuously corrected according to the rewind diameter
information coming from the driving system or from an ultrasonic sensor measuring the rewind diameter.
The taper function allows a perfect rewind roll shape (mainly avoiding telescopic effect).
You need the tension control connected to PLC.
Use RS232 communication.
You need an adaptive PID due to big diameter ratio.
Use internal or external PID correction.
Use RS232 communication to operate the correction.
You already have your own load cell.
MCS2000-CTLC can accept any signal.
You have flying splice on the machine.
MCS2000 can manage it.
You need to control a brake and a motor.
MCS2000 can control both.
You have a multi-material machine range.
Use memory card to load the correct programme.
Use RS232 communication to change the parameters.
Use Window software to load the correct programme.
You need taper function.
Use the right MCS2000 model including this function.
Your feedback is a 0-10 V.
MCS2000 can accept any signal range.
You need to work in open + closed loop.
MCS2000 is provided with both function.
You finally found a perfect setting.
Save it on a memory card as back-up.
You need to display the tension in Newton, kilo…
MCS2000 can be programmed for any unit.
You have a very special application.
We can assit you in control definition.
Ask Warner representative, we can propose any
customised solution / software.
MCS2000 line is provided with very interesting and useful features. Below is a brief
description of the most interesting ones.
CONTROLS
MCS2000 - Important features
As already stated, the main problem in tension control is the roll inertia change during operation. The PID function is
optimal for one inertia value. The MCS2000 line is provided with an important feature which is the PID correction. Based
on the available diameter information you can apply a continuous PID correction. When no information is available, an
internal PID change can be programmed.
Each parameter P, I and D can be set individually for the
smallest (core) and biggest diameter. As soon as the
correct parameters are found for the extreme diameter
value, they are stored. The diameter information provided
will fix the PID values for the present diameter value. This
will allow the system to keep an excellent stability during the
whole diameter evolution. In the case where the diameter
information is not available we can provide this signal by
installing a sonic sensor or by working with
internal correction. The external diameter information
supplied to the controller will ensure a better precision
compensation compared to an internal correction.
WHATEVER YOU NEED MCS2000 CAN REPLY …
D
I
P
Core
Diam. info
PID relative values
100%
50%
Typical PID values for TB brakes
31
32
MCS2000-CTOL-00 control is purely dedicated to the open loop control. There are
two main uses: diameter calculator and ultrasonic sensor roll measurement. This
control can be an alternative where the required tension precision is not critical .
CONTROLS
Open loop control - MCS2000, CTOL-00
Specifications
Input power supply
24 VDC ± 5%, 0,2 A
Analogue inputs
- Line speed
0-10 VDC
- Rotation speed
0-10 VDC
- Ultrasonic sensor
0-10 VDC
- Torque offset
0-10 VDC
- Torque setting
0-10 VDC
Pulse input for rotation speed
1, 2, 4 pulse/rpm
Analogue outputs
- Sonic diameter info
0-10 VDC
- Diam. Calcul info
0-10 VDC
- Main output signal
0-10 VDC
- % main output signal
0-10 VDC
Digital inputs
- Calculator reset
Active low
- Calculator freeze
Active low
- Fast stop
Active low
- Out OFF
Active low
- Out ON
Active low
- Out HOLD
Active low
Digital output
- Diameter level out
Relay, 24 VDC/0,2 A
T
T
Power
Driver
Control
Analogue signal or pulses
Tension setting
Any process machine
with driving nip rolls
Line speed info
Features
❐ Diameter calculator function.
❐ Ultrasonic sensor function.
❐ DV/dt compensation.
❐ Remote tension control.
❐ Automatic diameter value store.
❐ Master - % slave dual output.
❐ Initial reset calculator value.
❐ Dynamic friction compensation.
❐ Static friction compensation.
❐ Fast stop capability.
❐ Large 2 x 16 characters display.
❐ Taper function for rewind.
Standard application with diameter calculator
NEW
33
MCS2000-ECA
MCS2000-CTDA-10 / CTDA-11 / CTLC-10 / CTLC-11 / CTOL-00
(same physical dimensions)
CONTROLS
MCS2000 control line - Dimensions
Sens In
Sens+
Sens-
Opto+
SetPt+
SetPt-
k O.L.
F.S.
O.L.+PID
Lim.Out
Stop Int.
Synchro
A
B
C
RevSens
0V
O.L. Out
0V
RXD
TXD
0V
Ref+10V
0V
Analog 1
0V
Analog 2
0V
Analog 3
Opto-
Out2[A]
Out2[V]
Out[0]
Out1[A]
Out1[V]
Out1[0]
+24V
Level 1
Level 2
ErrSens1
ErrSens2
0V
+24V
0V
MCS2000
WARNER ELECTRIC
57
183
42
16
5
MCS2000-ECA
Dimensions [mm]
MCS2000-CTDA, MCS2000-CTLC, CTOL
255
275
295
20
42.5
15
1
90
WARNER ELECTRIC
MCS2000
MOUNTING
Front panel
mounting
Wall
mounting
DIN rail
mounting
Control
Control
Control
Symmetric
DIN rail
Front
Front
Front
Working in closed loop requires a web tension SENSOR. When working with load
cell the system is called “Direct Tension Feedback”. When working with dancer arm
the system is called “Indirect Tension Sensor”. Position sensors are divided in two cat-
egories : linear and rotary.
SENSOR
ACCESSORIES
Sensors overview
SENSOR OVERVIEW
DO NOT FORGET: The sensor is the most important element when working in closed loop and has to be accurate, with good repeatability.
• Place load cell in order to measure web tension, minimize the dead load and all other stress interferences on it.
• When using dancer solution create the desired tension with true force (pneumatic cylinder) and not with weight.
• When measuring distance avoid hysteresis in the movement. In general, sensor must be the exact image of the value we have to measure.
MODEL
TYPE / SYMBOL
RANGE
MAIN CHARACTERISTICS
ES01
End shaft load cell
❐ 50 N to 2000 N
❐ Typical output volltage :
❐ 6 tension ranges
20 mV at full load
❐ Resistive bridge
❐ 40 mm ball bearing diam.
ES02
End shaft load cell
❐ 250 N to 2000 N
❐ Typical output voltage:
❐ 4 tension ranges
20 mV at full load
❐ Resistive bridge
❐ 52 mm ball bearing diam.
FM01
Foot mounted load cell
❐ 100 to 5000 N
❐ Typical output voltage:
❐ 6 tension ranges
5 VDC at full load
❐ Resistive bridge
❐ Incorporated amplifier
FM02
Foot mounted load cell
❐ 5000 N to 10000 N
❐ Typical output voltage :
❐ 2 tension ranges
5 VDC at full load
❐ Resistive bridge
❐ Incorporated amplifier
MCS605-E
Rotary
❐ ±100°
❐ Typical output voltage:
❐ Resistive conception
± 3.75 VDC for
± 15 VDC power supply
and ± 30°
MCS705-E
Rotary
❐ ± 100°
❐ Typical output voltage:
❐ Optical conception
± 3.75 VDC for
± 15 VDC power supply
and ± 30°
SCUA-030
Linear
❐ 0 to 1 m
❐ Typical output voltage:
❐ Ultrasonic measure
0-10 VDC for 0 - 1m
SCUA-040
Linear
❐ 0 to 3 m
❐ Typical output :
❐ Two distance ranges
0-10 VDC for
❐ Ultrasonic measure
nominal distance
MCS905-E
Linear
❐ 50 mm stroke
❐ 5-30 VDC power supply
❐ Resistive conception
Self-aligning bearing
2k resistor
34
35
35
36
36
37
37
38
38
38
35
END SHAFT LOAD CELLS are normally used in new machines designed with the
possibility to place the load cell directly on the sensing roll. The end shaft version
offers the advantage of being able to easily place the load cell in any tension resultant
direction. The ES model exists in two versions differenciated with the diameter of ball
bearing which has to be placed in.
SENSOR
ACCESSORIES
End shaft load cell type ES
END SHAFT TYPE ES01-...and ES02-...
All end shaft load cells are based on the Wheatstone bridge principle. They have no built in amplifier. They are
delivering a signal which is proportionnal to the voltage supply and tension applied. It is important to respect the
measurement direction referenced on the load cell body (normally an arrow indicates the sensitive direction).
ES..-... LOAD CELL FEATURES
ELECTRICAL CONNECTIONS ES01-... and ES02-…
IMPORTANT:
ES01-40C requires a ball bearing with external
diameter 40 mm
ES02-52C requires a ball bearing with external
diameter 52 mm
Ball bearing must be self aligning type to allow web
tension measurement only (no other external constraints).
AVAILABLE MODELS / CAPACITY
ES01-40C and ES02-52C
Power supply
10 to 15 VDC / 40 mA (±5 VDC in Warner control)
Sensitivity
2 mV / V supply at nominal load
1 mV / V supply for 50 and 150 N models
Rating
50-150-250-500-1000-2000 N
Connections
5 m shielded cable supplied
Mechanical overload
Max 150 % in any direction
Dimensions
See mounting instructions ref. MC481 and MC482
Mounting
See recommendations on page 11
Nominal
50 N
150 N
250 N
500 N
1000 N
2000 N
ES01-...
-50-40C
-150-40C
-250-40C
-500-40C
-1000-40C
-2000-40C
ES02-...
-
-
-250-52C
-500-52C
-1000-52C
-2000-52C
Red
+15 VDC
Green Signal -
Yellow Signal +
Blue
-5 V supply
Shield
Cable supplied
36
The foot mounted load cell is the ideal solution for machine retrofiting or for heavy
tension measurement. The foot mounted model has to be installed with a pillow block
type ball bearing supporting the sensing shaft.
FM01-.... and FM02-.... are only differenciated by the physical dimensions.
SENSOR
ACCESSORIES
Sensors / Accessories
FOOT MOUNTED TYPE FM01-…. and FM02-….
Specifications (all FM SERIES)
Foot mounted load cells are available in two versions:
With incorporated amplifier.
FM……..-AC
Without amplifier.
FM……..-C
AC = amplifier and connector on the load cell body.
C = connector on load cell body.
ELECTRICAL CONNECTIONS FM….-AC
ELECTRICAL CONNECTIONS FM…..C
SETTING (FOR FM…..AC only)
Load cell is factory scaled for:
- No load – 0V output.
- Nominal load – 5V output.
The load cell does not need to be scaled for normal use in
closed loop. However, a rescaling after installation is
possible by using potentiometer and LED indicators.
AVAILABLE MODELS / CAPACITY
Nominal
100 N
250 N
500 N
1000 N
2500 N
5000 N
10000 N
FM01..-
-100-AC
-250-AC
-500-AC
-1000-AC
-2500-AC
-5000-AC
FM01..-
-100-C
-250-C
-500-C
-1000-C
-2500-C
-5000-C
FM02..-
-5000-AC
-10000-AC
FM02..-
-5000-C
-10000-C
Green LED
D-Sub connector
Zero setting
Green LED ON above 0 VDC
Gain setting
Green LED ON below 5 VDC
Red
+15 VDC
White 0V
Yellow Signal
Blue
-15 VDC
Cable supplied
Red
+5 VDC
White Signal -
Yellow Signal +
Blue
-5 VDC
Cable supplied
FM……..-AC
FM……..-C
Power supply
±12 to ±15VDC
± 5 VDC or +10 VDC
Sensitivity
0-5 VDC, nominal load
10 mV, nominal load
Rating
100 – 250 – 500 – 1000 – 2500 – 5000 – 10000 Newton
Connections
Cable supplied, see below
Permitted overload
- Compression
150 %
- Extension
120 %
Radial permitted force
50%
Dimensions
See mounting instructions ref. MC480
Mounting
See recommendations on page 11
37
POSITION SENSOR
A position sensor is used in 2 possible ways:
❒
To detect dancer moving in the closed loop installation working on dancer principle.
❒
To sense the diameter of the roll to operate open loop control or make PID
compensation in closed loop installation.
SENSOR
ACCESSORIES
Rotary sensors
ROTARY SENSOR
ELECTRICAL CONNECTIONS
- Supply
+ Supply
Signal
3
2
1
4
View from outside
White +15 V
Green Signal
Brown -15 V
Shield
Cable delivered in mounting Kit option (see page 40).
MCS605-E
MCS705-E
Power supply
10 to 30 VDC / 30 mA
10 to 30 VDC / 30 mA
(or ± 5 to 15 VDC)
(or ± 5 to 15 VDC)
Max detection angle
200° or ± 100°
200° or ± 100°
Sensitivity
2,5 mV / V / °
Option :
Mounting kit
See page 40
See page 40
TB Brake
Sensor
Working in closed loop with the arm dancer principle is
very popular especially in the printing market where a
good flexibility of the system is required to absorb the
eventual “tension peaks”. The rotary sensor is necessary to
read the dancing roll movement.
MCS605-E and MCS705-E are ideal for easy mounting.
They are encapsulated in rugged metal housing preventing
mechanical shocks. Furthermore they are provided with
built in switch in order to change the signal output
polarity.
Optional mounting kits facilitating quick and easy fitting on
the machine are available. Each kit is composed with
brakets, cable, coupling and screws (see page 40).
38
In the tension control market ultrasonic sensors have two primary uses:
❒
For roll diameter reading when the system operates in open loop.
❒
For loop position reading when the system operates in closed loop with dancer arm
principle.
SENSOR
ACCESSORIES
Ultrasonic sensors & linear sensors
ULTRASONIC SENSORS TYPE SCUA….
LINEAR RESISTIVE POTENTIOMETER
ELECTRICAL CONNECTIONS
White +15 V
Green Signal
Brown -15 V
Shield
Cable with connector for SCUA-030
Cable attached for SCUA-040/080.
Slightly misaligned
Recommended sonic position
to guarantee a good reading
reliability on the core.
Fine dancer position
MCS905-E
Power supply
5 to 30 VDC
Resistor value
2 K
Electrical stroke
50 mm
Fixation
2 self aligning bearing
Cable
0,5 m attached
- Red and Black
Voltage supply, not polarised
- Yellow
Wipper (output signal)
SCUA-030
SCUA-040/080
Power supply
18 to 30 VDC/45 mA
18 to 30 VDC/70 mA
Analogue output
0-10 VDC/ 0 – 1m
0-10 VDC/0-2-3 m.
Digital output
Adj. from 0,15 to 1 m
Adj. from 0,2 to 2,3 m.
Min measure distance
0,15 m
0,2 m
Max measure distance
1 m
2m / 3 m
Housing
Cylindric M18
“Cube”
Accessory
1, 5 m cable delivered
Mounting bracket
3 m cable attached
Option
6 m cable
reference : SCUA-032
Dimensions
See mounting
See mounting
instructions ref. MC485
instructions ref. MC486
39
All material not entering in the main open or closed loop function is listed in the
ACCESSORY chapter. This concerns mainly power supply, cable, programming tool,
display, amplifier ….
SENSOR
ACCESSORIES
MCS2000 line - Accessories
MCS2000 LINE – ACCESSORIES
DESIGNATION
MAIN CHARACTERISTICS
MCS2000-PRG
Hand programmer for MCS2000-ECA.
2 x 16 characters display.
Powered from MCS2000-ECA.
Connectable and disconnectable during operation.
Cable supplied.
MCS2000-CRD
Memory card for MCS2000-line.
Compatible ECA, CTDA, CTLC.
2 full programmes capacity.
Easy load and downloading to control unit.
Automatic downloading to control unit.
Dimensions : 40 mm x 15 mm.
MCS2000-IS
Load cells amplifier and Sonic
Power supply: 24 VDC ± 10%, 300 mA
sensor interface.
Input load cells: 2 inputs - from 2m mV to 10 V / 5 K
Use as load cells amplifier and adder
Input sonic:
1 input – delta voltage min 2 V
when two load cells are connected.
Other inputs: 0-10 VDC / 10 K
Can accept any load cell signal
Signal output: 2 ouputs – 0-10 VDC
comprised between 20 mV and 10 V.
Power output: ± 5 or 15 VDC to power load cells
Usable as sonic interface for low cost
+24 VDC to power sonic.
open loop tension control.
MCS2000-DP
Pannel mounted programmer + display
2 x 16 characters lines display.
for MCS2000-ECA .
Powered from the MCS2000-ECA.
(Same characteristics as
MCS2000-PRG but designed
for panel mounting).
MCS2000-PS
24 VDC power supply unit.
Power supply: 100 –250 VAC autoranging
Output:
24 VDC ± 5%, 3,1 Amps
MCS2000-PLC
List of codes available on request.
RS232 communication for MCS2000 line.
MCS2000-WIN
3 diskettes or E-mail transmittable.
Compatible Window 95 - 98.
To programme MCS2000 control line.
40
MCS2000 product line supports RS232 communication. Every unit of the line can be
connected to a PLC in terminal mode or / and programmed with PC.
Using terminal mode requires various codes to transmit to the unit. Using the PC to
programme the unit requires installation of Warner Electric software (windows
compatible). Both options are available.
SENSOR
ACCESSORIES
Rotary sensors - Accessories
MCS605-E - ACCESSORIES
The
MCS202-Exx is designed to work with dancer arm principle. Usually the sensor is a rotary type.
Warner sensor
MCS605-E and
MCS705-E can be delivered with complete mounting kit.
Mounting kit comprises of
CABLE, COUPLING, BRAKETS and all necessary
SCREWS. Various
KITS are differenciated
with various length of cable and cable with or without connector at control end side.
MCS2000 line requires free leads
(MCS2000 control line is provided with terminal block).
MCS202-Exx requires a connector
(MCS202-Exx is provided with the connector).
DIMENSIONS - MOUNTING
Cable length
One / Two connectors
Compatible
MCS-KIT1
3 m
2
MCS202-Exx
MCS-KIT2
3 m
1
MCS2000
MCS-KIT3
4,5 m
2
MCS202-Exx
MCS-KIT4
4,5 m
1
MCS2000
MCS-KIT7
6 m
2
MCS202-Exx
MCS-KIT8
8 m
1
MCS2000
50,8
130
65
18
min 47 / max 70
?38,1
3 x ?45
57
57
3 x 120
°
Coupling
?
6,35
45
21,9 14,2
38
,1
?
6,5
31,6
41
The WARNER ELECTRIC experience enables us to offer a tension guide as shown
below. For any special material not included in the chart below, please consult
WARNER .
Tension selection
6
4
2
0
0
20
40
60
80
100
120
140
Te
nsion f [N
/cm]
Weight PW [g/m2]
PVC
Polyethylene
6
4
2
0
0
0,2
0,4
0,6
0,8
1
1,2
1,4
Tension f [N
/cm]
Thickness [mm]
AL
CU
Diameter [mm]
120
80
40
0
0
0,5
1
1,5
2
2,5
3
3,5
Tension f [N]
PAPER WEIGHT
F = f x width [cm]
FOIL
F = f x width [cm]
WIRE
MATERIAL DENSITY
kg/m3
Paper
920
Paper board
1420
Alu foil
2720
Alu wire
2750
Cu wire
8550
PVC
400-1050
Unwider stand
Nip roll
Rewind stand
Which type of machine is it ?
♦ Printer, Slitter, Sheeter, Coater, Laminator, …or other ?
Which machine part concerned
Which web material is it ?
Max / min tension (if known)
Characteristics of the material
♦ Paper weight
Gr / m2
♦ Plastic film thickness
mm
♦ Wire diameter, matter
mm
♦ Other (short description)
Characteristics machine
♦ Auto flying splice
Yes / No
♦ Zero speed splice
Yes / No
♦ Max linear speed
M / min
♦ Min linear speed
M / min
♦ Max acceleration time
M / min / sec
♦ Normal deceleration time
M / min / sec
♦ Emergency stop time
M / min / sec
♦ Taper tension requested
+ or - %
Roll characteristics
♦ Weight
Kg
♦ Max diameter
mm
♦ Min diameter
mm
♦ Max width
mm
♦ Min width
mm
General information
♦ Is it a new project or a retrofit ?
♦ Loosing tension permitted in
Yes / No
emergency stop case
♦ If machine working in cycle,
Time in sec.
what’s the cycle rate ?
Speed in m/min
♦ Is the brake or motor direct
Roll/ brake
on shaft or gear mounted ?
(rpm)
♦ Which brake or
Electromagnetic
motor technology ?
brake
Motor
♦ Which control configuration ?
Open loop /
Closed loop
To enable us to assist you in selecting the best product type and specification to
ensure reliable and accurate tension control, please submit this APPLICATION
FORM.
Data application Form
Please complete this form as much as possible. Please also include any other information of interest.
Company name:
Adresse:
City:
Country:
Contact name:
Phone / fax:
e mail:
Speed
Time
Max speed
42
TORINO
Direzione generale:
Via Mappano, 17 - 10071 Borgaro T.se (TO)
T +39 011 451 8611 (centr. r.a.) - F +39 011 470 4891
setec.to@setec-group.it
MILANO
Via Meccanica 5
20026 Novate (MI) - Z. I. Vialba
T +39 02 356 0990 - 382 01 590 (r.a.)
F +39 02 356 0943
setec.mi@setec-group.it
PADOVA
Via Secchi 81
35136 Padova
T +39 049 872 5983
F +39 049 856 0965
setec.pd@setec-group.it
BOLOGNA
Via Del Lavoro 6/A
40051 Altedo (BO)
T +39 051 871 949 (3 linee r.a.)
F +39 051 870 329
setec.bo@setec-group.it
FIRENZE
Via Galileo Galilei 3
50015 Bagno a Ripoli - Grassina (FI)
T +39 055 643 261
F +39 055 646 6614
setec.fi@setec-group.it
www.setec-group.it
