ATO STC858A User manual
AUTOMATIC TENSION CONTROLLER
INSTRUCTION MANUAL
TENSION CONTROLLER
MODEL - STC858A
English version
Ver 3.0
安全注意事项
为了保证安全使用本产品
●在安装和使用之前，请务必详细阅读本说
明书，一定要注意安全，正确使用本产
品，并遵守本说明书中的各种规定。
●基于VDE0160。本产品是采用CPU控制的电
子设备，用来控制设备的张力，所以要严
格遵守电子设备有关规定和法则，适用标
危险
如果错误操作，将会产生危险情况，导致
死亡或受重伤。
注意
如果错误操作，将会产生危险情况， 造成
设备损坏或财产损失。
■设计注意事项
(请务必在使用前阅读)
■ 安装及环境
■ 安装与配线
危险
注意
►切勿在有起火、爆炸危险的环境中使用，以免引发火灾、爆炸的危险。
►切勿私自改造、拆卸该产品。否则会导致产品故障、引发火灾或造成产品损
坏等事故。
►请勿将该产品安装在有灰尘、油烟、异性尘埃、腐蚀性气体、可燃性气体的
场所，勿使其暴露于高温、结露、风雨等恶裂环境中,勿将其安装在易受振动
冲击的场所。否则会损坏产品，导致其误动作或恶化。
►本产品报废时，请将其作为工业废弃物进行处理。
危险
注意
►请务必使用满足电流容量的电线。
►紧急停止电路请务必直接安置在外部,切勿使其通过张力控制器。
►机械的停止电路请务必直接设置在外部,切勿使其通过张力控制器 ，否则当
张力控制器误动作时，会使机械失控而引发事故。
►配线时请务必使用满足电流容量的电线，若电线过细，则会使绝缘包皮熔化
而导致绝缘不良，还可能引发触电、漏电及火灾等。
注意
►在打开控制器准备安装和接线之前要断开控制器外部所有电源至少要5分钟,
否则将导致触电或损坏产品。
►请务必在产品的接地端子上使用2mm2以上的电线进行接地（接地电阴100Ω或
更小）,否则将导致触电。
►请务必将强电电线与弱电电线分开配线，并勿将其共同接地。否则将会使弱
电线上的噪音叠加，导致误动作。
►切勿让铁屑或零碎电线落入产品中，否则会导致产品损坏、冒烟、起火、误
动作等危险。
■试运行
注意 ►请勿用湿手进行开关各 键 的 动 作 ， 否 同会导致触电。
►在通电和运行中请确认盖子已拧紧，否则会触电危险。
►在使用前，要除去所有覆盖物，以防止装置过热。
!
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®
Cautions on Safety
(Make sure to read this page before using the unit.)
In this manual, cautions of safety are classified into "DANGER"
and "CAUTION". Even an item is classified as "CAUTION", its contents are
important and it may lead to a serious result depending on the
situation. Make sure to observe every item.
Danger:
Caution:
When the unit is handled incorrectly, a
dangerous situation may occur and the
possibility of death or serious injury is
expected.
When the unit is handled incorrectly, a
dangerous situation may occur and the
possibility of medium or slight injury is
expected or property damage exclusively
is expected.
Never use the unit in an atmosphere where
inflammation or explosion can occur.
Danger
Otherwise, inflammation or explosion may occur.
Set up the emergency stop circuit
independently of the product.
Otherwise, the unit may become out of order and an
accident may occur when malfunction occurs in the
tension controller. Make sure to assemble the
emergency stop circuit outside the tension controller.
Danger
Do not use any unused terminals for any
external lines.
Correctly connect the AC power cable to the specified
terminal, and do not use any unused terminals for any
external lines. Improper connection may seriously
damage the product.
Caution
Never touch a switch with a wet hand.
Danger
Never touch a switch with a wet hand, otherwise,
electrical shock may occur.
Never drop cutting chips and wire chips
while screw holes are tapped and wiring
work is performed.
Damage, fume, fire, malfunction or others may be
caused in the unit.
Danger
Confirm the ambient enviroments.
Never install the unit with an enviroment where dusts, soot,
conductive dusts or corrosive gas is present or a place
exposed to high temperature, condensation or wind and
rain. Otherwise, the unit may be damaged, malfunction or
be deteriorated.
Caution
Never open the covers while the power is
supplied to the unit or when the unit is
operating.
Never supply the power to the unit nor operate the unit
while the main body cover and the terminal cover are
open. When the covers are open, a high voltage area
may be exposed and electrical shock may occur.
Danger
Turn off all the phases of the external power
supply before starting installation and wiring.
Danger
Otherwise, electrical shock or damage in the unit may
occur. Make sure to turn off all the phases of the
external power supply before starting installation and
wiring.
Separate the wiring of the strong electric
system from the wiring of the weak electric
system.
Caution
Separate the wiring of the strong electric system from the
wiring of the weak electric system, and make sure that
noises are not superimposed on the wiring of the weak
electric system. Otherwise, the unit may not operate
correctly.
Danger
Never modify nor disassemble the unit
Never modify nor disassemble the unit. Otherwise, the
unit may become defective or an accident such as fire,
damage, etc. may occur.
Danger
Design the installation plan using the wire
size suitable to the current capacity.
Use the wire size suitable to the current capacity to
supply the power to the load. If a wire having smaller
current capacity is used,the insulation sheath will be
melted and insulation will become defective. In this
situation, electrical shock or a short-circuit may occur,
and fire may occur.
To assure safety
>Make sure the user thoroughly read this instruction manual
before using the unit, and pay attention in assuring safety
while using the unit.
>The unit is manufactured under the severe quality control.
When a severe accident or loss is expected in the
equipment used due to failure of the unit, provide a backup
function or the fail-safe function in the system.
Perform grounding ( grounding registance
100
Ω
or less).
Danger
Otherwise, electrical shock may occur. Perform
grounding ( grounding registance 100
Ω
or less) to the
unit using a wire of 2 mm
2
or more, otherwise, electrical
shock may occur. Never share the grounding with a
strong electric system.
MODEL - STC858A
LTC858A
CONTENTS
1. Outline
1.1 ............................................... 1Outline
1.2 Functions and features ................................. 1
1.3 ................ 2Panel configuration& Functions of DIP switches
2. Installation and Wiring
2.1 Dimensions ........................................... 4
2.2 Installation ............................................ 4
2.3 Wiring .................................... .... 5........
3.Screen system & operation
3.1 Screen system ..................................... 7
3.2 Screen introduction.................................... 8
3.3 Parameter initialization................................ 9
4.Automatic tension controlling
4.1 Tension measuring .................................. 10
4.1.1 Tension detector installation & wiring ....... .... 10...
4.1.2 Tension measuringparameter settings .............. 11
4.1.3 Tension demarcate ............................. 12
4.2 Adjustment & initial setting ........................... 14
4.2.1 Manual controlling ............................... 14
4.2.2 Automatic controlling.............................. 14
4.2.3 PI parameter setting .............................. 15
4.2.4 Operation at starting or stopping machine ........... 16
4.2.5 Dual axis switching ................................ 17
4.2.6 Speed up/slow down controlling .................... 19
4.2.7 Alarm function .................................... 20
4.2.8 Feedback method ................................. 20
4.2.9 Second output .................................... 20
4.3 Taper tension controlling.............................. 21
4.3.1 Outline of taper tension controlling................. 21
4.3.2 aper .................... 21T tension run mode screen
4.3.3 Tapeer .......... 21 tension controlling debugging steps
5.Other functions
5.1 Language select .......................... ......... 22
5.2 Parameter backup . ................................. 22
5.3 Restore default settings ............................... 22
6.Inspection and maintenance......................... 23
7Appendixes.
7.1 Parameter screen.................................... 24
7.2 Tension detector operation principle.................... 25
7.6 Technical specifications .............................. 27
7.3 Dimension specification............................... 26
7.4 Assembling drawing.................................. 26
7.5 Tension detector installation.......... ............ 26.....
MODEL - STC858A
1.1 Outline
Tension detector
STC858A
Powder brake
➲ G simple raphical LCD display 128x96 with the capability of dispaly Chines and English characters, it has
➲ Multi-function select: automatic tension controller with taper tension controlling function.
➲ Using high precision D/A converter, and the output precision reach to 0.1%, and which makes the tension
➲ Can drive the powder clutch/brake directly, also can control frequency converters, servo motor and electro-
➲ Can receive the single-way or double-wayinput signal from tension detector and with automatic zero
➲ With Dual axis switching and speed up/slow down controlling function 。
➲ With password settings function which can avoid changing set parameter when it operated incorrectly.
➲ With memory cassette which can backup various parameter.
➲ With human interface design which is very easy to operation.
1.2 Features
Automatic tension controller
Chapter 1 Product outline
1
STC858A tension controller is a full digital tension controller with high precision and multi-function which to match up
tension detector to form a closed-loop tension controller system an then receives the signal from LS series tension
detector after intelligent PID operation processing internally, regulating implementing structure and to auto
matically
control the tension of the long material at the unwinder, feed reel, and winder.
STC858A tension controller uses a new graphical LCD display which Chinese and English display clearer and then generates
a control voltage of 0 to 24V DC to control the powder clutch/brake and the hysteresis clutch/brake, or generates the torque
command voltage of 0 to 10V to send to the servo amplifier.
controller with high precision, more stable and reliable。
p。rogramming and easy to operate.
pneumatic converter...
set and automatic calibration.
MODEL - STC858A
%
自动运行
设定值
实际值
输出值
10.0Kg
10.0Kg
50.0%
MONITOR
SELECT
POWER
AUTO
ONOFF
ESC
SET
MAN
OUTA OU TB ALM COM
mm
Kg/N
自动运行
设定值
实际值
输出值
10.0Kg
10.0Kg
50.0%
输出
OUTPUT
ON-OFF
手动 自 动
选择
键锁
1.3 Panel configuration
1. LCD display
22.Monitor display 2. Lockin LED
3. Lockin key
18. Output On/Off LED
17. Output On/Off key
15. , up key▲
16. ,down dey▼
13. Set, confirm key
21. LED indicator
14. Esc, cancel key
20.Screen selection keys
8. Setting dial
4. Auto indicator LED
6. Manual indicator LED
7. Auto/Manual control switch
5. Open screw
9. OUTA, A shaft input indicator
10. OUTB, B shaft input indicator
11. ALM, tension alarm indicator
12. COM, communications indicator
2
23.Power indicator
24.ower switchP
1Set/Esckey:using these two keys to select or to confirm settings.
Set key: enter sun-menu or confirm operation.
Esc key: Return to previous menu or confirm return.
2
Using this key to switch to auto control mode or manual control mode freely.
Output On/Off LED &key
Pushing this key to control output on & off, repeat this key, the output will be swift to on or off.
When the output on/off indicator lighting which allows output;
When the output on/off indicator unlighting, then the LED display is off and the output value is 0.0%.
4.
When pushing this key, there will display tension measuring value(kg/N indicator lighting), output power
(% indicator lighting),roll diameter(mm indicator lighting).
.
. Auto/Manual control switch
3.
Screen selection keys &LED indicator
5. Lockin key
When the tension controller is at “auto control” or at “manual control”interface, the key is to lock (avoid
operating incorrectly) or unlock. Once the key is locked, then the up key, down key, auto/manual control
When the lockin indicator lighting which means it locked, when the lockin indicator unlighting which means it unlocked.
6. Output indicator :
It's green indicator, and the lightness of the indicator is connected to the output power,the lighter of the indicator the higher of the power.
When the power is zero, then the output indicator will turn off.
switch, output On/Off key and setting dial will not work.
MODEL - STC858A
7. OUTA : A shaft output indicator
It's red indicator. when the A shaft outputting, the indicator will light.
8. OUTB : B shaft output indicator
It's red indicator. When the B shaft outputting, the indicator will light.
9. ALM : tension alarm indicator
It's red indicator. During tension system working, when the tension is less than tension alarm value[04] AL1,
hen system starting/stopping,aixnl,zero tension alarm will not alarming. works and generates alarm signal. W
10. COM:communications indicator
It's red indicator. When LTC858A receives the valid command response- return data from upper station,
3
*[04]parameter of , numbers inside[] shows parameter serial number. All the parameter show this way.tension controller
*
.
ZT relay
then COM indicator lights.
MODEL - STC858A
KTC838
Tension Controller
OUT
mm
%
kg/N
OUTPUT
ON/OFF
MANUAL
AUTO
COM
LOCK
ALMOUTA OUTB
AUTO
MAN
Set Esc
4-M4
80+
-
0.5
Dimensions of screw holes for floor or wall mounting.
232 +
-
0.5
150+
-
0.5
Panel cutting dimensions for panel mounting
245
228
16.5 140
147
154
60
60
2.1 Dimensions
2.2 Installation
256
168
Floor mounted
172.5
Wall mounted Installed on Panel
4-M4*12
Mounting screw
2～4mm
140
Chapter 2 installation and wiring
4
Unit:mm
244 +
-
0.5
%
自动运行
设定值
实际值
输出值
10.0Kg
10.0Kg
50.0%
MONI TOR
SELE CT
POWE R
AUTO
ONOFF
ESC
SET
MAN
OUTA OUTB A LM C OM
mm
Kg/N
自动运行
设定值
实际值
输出值
10.0Kg
10.0Kg
50.0%
输出
OUTPUT
ON-OFF
手动 自动
选择
键锁
%
自动 运 行
设定 值
实际 值
输出 值
10.0Kg
10.0Kg
50.0%
MON ITO R
SEL ECT
POW ER
AUT O
ONOFF
ESC
SET
MAN
OUT A OUTB A LM CO M
mm
Kg/N
自动 运 行
设定 值
实际 值
输出 值
10.0Kg
10.0Kg
50.0%
输出
OUT PUT
ON-O FF
手动 自 动
选择
键锁
►Never drop cutting chips or wire chips while screw holes are tapped and
wiring work isperformed. Otherwise, damage, fume, fire, malfunction or other
may be caused in the unit.
Make sure to turn off all the phases of the power supplies outside before starting
• When you install the controller to the floor or wall, be sure to use the screws supplied with the
controller to fix the plate to the controller main body. If you use screws 10 mm or longer, the
screws may contact the inner parts of the controller main body.
Screw tightening torque = 0.5 to 0.8 N m.
• Using a screw hole where no screw is tightened to fix the mounting plate, perform grounding
( grounding registance 100Ω or less) of the sheet metal area.
►
Danger
!
CAUTION
!
Sunr ise Gro up (HK) I ndust rial Co ., Limi ted
TEN SION CO NTROL LER
MOD EL： STC 858
POW ER： 85~ 264VAC 5 0/60H z
INP UT： 0~3 00m V
OUT PUT：24 VDC/4 A MAX
0~1 0VDC
www.s unri sesc n.co m
MADE IN TAI WAN
Sunrise Group (HK) Industrial Co., Limited
TENSI ON CONTR OLLER
MODEL： S TC858
POWER： 8 5~264 VAC 50/60 Hz
INPUT： 0~300m V
OUTPU T：24VDC/ 4A MAX
0~10VD C
www.sunrisescn.com
MADE IN TAIWAN
Sunrise Group (HK) Industrial Co., Limited
TENSI ON CONTR OLLER
MODEL： S TC858
POWER： 8 5~264VA C 50/60 Hz
INPUT： 0 ~300mV
OUTPU T：24VDC/ 4A MAX
0~10VD C
www.sunrisescn.com
MADE IN TAIWAN
and wiring. Otherwise, electric shock or serious damage to the unit may occur.
The tension controller can be floor, wall or panel mounted.
MODEL - STC858A
2.3 Wiring
Wiring 1: Wiring 2:
2.3.2 Basic wiring
NB
PB
NA
PA
*
Main shaft pulse input
RS485communication
Reserve output selection switch
speed up switch
axis switching
in-phase output 0 10V～
(connect A shaft power)
Second output0 10V～
(connect B shaft power)
Zero tension alarm output
A shaft powder clutch/brake
0～24VDC/4A
(160～240VAC)
Power supply
+24V
DI0
DIA
DIB
GND
MC4
MC5
MC2
MC1
MCC
TRG
TR-
TR+
ZTC
ZT
EAP
EAN
SA
Starting/stopping switch
SN
PSL
PSN
Tension detector
(Left)
power + (red)
signal - (green)
power - black)
ZT
Tension detector
(Right)
signal + (yellow)
signal - (green)
+
-
+
-
*NPN pulse signal
0～24VDC/4A
B shaft powder clutch/brake
}
}
}
}
2.3.1 Wiring method and cautions
5
PSL PSN ZTC NA NB
ZT ZN PA PB
DIO DIA
DIB
YEL
GRL
RED BLK
SG SG
YER
GRR
AIN1
+10V
AIN2
AGND
EAP
SN TR+
TR-
GRL
SG
YER
BLK
RED
YEL
SG
GRR
signal + (yellow)
shield
shield
MCC
MC1
MC2
MC3
MC4
MC5
MC6
GND +24V
M3.5
sselro8.7
sselro8.7
!CAUTION
MC3
MC6
Slow down switch
Reset switch
➊
➋
➌
➍
➎
Use the crimp-style terminals. Dimensions shown in the right figure.
Apply a torque of 0.5 to 0.8 Nm to each terminal, and carefully tighten each
terminal so that abnormal operation cannot be caused.
Use the shielded cables for the analog input/output line signal and the
winding roll pulse input line, and perform grounding ( grounding
registance 100Ω or less) on the signal receiving side.
Do not insert both the input/output cable and the power cable into the
same duct. Do not bind these cables together.
Generally, set the cable length to 10 m or less to protect the controller from noises.
➲
connection may damage the product.
➲Separate the low power cables from the high power cables, and do not connect both types of cables to the same grounding terminal.
The noise of the high power cable may be superimposed on the low power cable, hence abnormal operation may be caused.
➲Even if the cable is too long, do not insert the remaining part of the cable into the casing of this tension controller to prevent abnormal
operation.
➲Do not lay the AC power cable on the panel to prevent abnormal operation.
Correctly connect the AC power cable to the specified terminal, and do not use any unused terminals for any external lines. Improper
EAN
SA
+10V
AIN1
AIN2
AGND
Multifunctional Analog Channel Power
Multifunctional Analog Input Channel 1
Multifunctional Analog Input Channel 2
Multifunctional Analog Ground Wire
MODEL - STC858A
2.3.3 Wiring terminal
Wiring 1:
Item
1
2
3
4
5
6
7
8
9
10
11
Name
PSL, PSN
ZT, ZTC,ZTN
PA NA,
PB, NB
MCC
MC1
MC2
MC3
MC4
MC5
MC6
Technique parameter Specification
Input
Output
Output
Output
Input
Input
Input
Input
Input
Input
Input
Voltage 85~264VAC
Type
Connecting 220VAC power
Zero tension alarm output
Connecting A shaft powder clutc/brake
Connecting B shaft powder clutc/brake
Common terminal for external output on/off singnal
Input terminal for external starting/stopping controlling signal
Input terminal for external double axis controlling signal
Input terminal for reserve output selection switch
Input terminal for external slow down controlling signal
Output 24VDC/4A
Output 24VDC/4A
1
2
3
4
5
6
7
8
9
10
11
Name
YEL
GRL
RED
BLK
YER
GRR
SA, SN
EAP, EAN
TR+,TR-
+10V, AGND
AIN1, AIN2
Technique parameter Specification
Input
Input
Output
Output
Input
Input
Output
Output
Input
Output
Output
Type
Input signal of left tension detector-
Power supply+ of left tension detector
Power supply of left tension detector-
Input signal + of right tension detector
Input signal of right tension detector-
Second output 0-10V (connecting B shaft power)
Rs485 communication port
Input signal range 0~300mV
or 0~30mV
0-10V
Input signal range 0~300mV
0~30mVor
Output power voltage 5V
10Vor
6
!DANGER
12
13
+24V, GND
DI0 Input
Output
Input terminal for main shaft proximity switch
Max. frenquency 15kHz
➲
of all the phases is not cut off, you may receive an electric shock, or the product may be seriously damaged.
➲For the grounding terminal of the product and for the sheet metal area of the casing, be sure to perform grounding ( grounding
registance 100Ω or less) using wires of 2 mm2 or more. If grounding is not performed properly, you may get an electric shock.
➲Determine each cable diameter depending on the current capacity. If a cable is too thin, the insulating sheath of the cable may
melt. Use of such a cable may cause electric shocks, electric leakage, or fires.
➲At the completion of wiring, be sure to attach the terminal cover supplied with the product to prevent electric shocks, and then
supply power to the product.
Before installing the controller or performing the wiring work, be sure to externally cut off the power of all the phases. If the power
Input terminal for external speed-up controlling signal
Input terminal for taper reset
Power supply for external proximity switch(rotary encoder)
Item
Input signal + of left tension detector
Wiring 2:
In-phase output 0-10V (connecting A shaft power)
Connecting RS485
10V/50mA Backup power
Standby Analog Interface
MODEL - STC858A
3.1 Overall of screen system
AUTO
MAN
Set
Set
Esc
Set Set
Esc Esc
Password：808
Password：818
Set
Parameter adjustment screen
Parameter initialization screen
Esc Esc
Auto control
Measuring value: 24.9kg
Setting value: 25.0kg
Output value: 39.5%
Manual control
Measuring value: 24.9kg
Setting value: 25.0kg
Output value: 39.5%
Tension measuring value
Left tension: 24.9kg
Right tension: 25.0kg
Tension: 49.9kg
Password input
Password: 800
Set-confirm Esc-return
Chapter 1 Screen system
Power-on
Tension controller
STC858
7
www.ato.com
For 3 seconds
For 3 seconds
Set For 3 seconds
Set
Pushing 3 seconds
26.Communications
04.Tension alarm value
05.proportional band
03.Taper factor
06.Integral timer
07.Dead band
08.Reserve output
09.Start timer
10.Stop gain
11.Stop timer
12.axioincisal output
13.axioincisal timer
14.auxiliary output
27.Reeling method
15.auxiliary time
28.Feedback method
16.Speed-up factor
19.In-phase starting/stopping
17.slow-down factor
29.Second output
18.Setting range
02.Output filter
01.display filter
20.Output range
30.zero tension setting
21.Left error revising
31.Full-scale calibration
22.right error revising
23.tension detector selection
33.Parameter Backup
24.display unit
34.Factory Reset
▲
25.signal rnage
04.Tension alarm
05.Proportional band
03.Taper factor
06.积分时间
07.Integration time
08.Prepare output
09.Start time
10.Stop gain
11.Stop time
12.Axis cut output
13.Time for cutting axis
14.Auxiliary output
15.Auxiliary time
16. Acceleration factor
17. Deceleration factor
02.Ouptput filter
01.Display Filter
▲
32.Chnese/English
Priority order for screen selection at power-on.
(1) Memory cassette insertion screen
(2) Parameter initialization screen
(3) Adjustment mode screen
Rotary knob to select the
specific numerical settings
menu, press the Set button
to enter the setup screen
for programming.
MODEL - STC858A
3.2 Main Screen Introduction
(1) Automatic control - constant tension mode screen
(2) Automatic Control - taper tension mode screen
(4) Monitoring tension testing value
(5) Password setting
(6) Parameter screen
Using up key /down key or value knob to select the setting parameter,
Press "set" to enter to Paramenter screen.
Press Esc key to save and exit.
Using up key /down key or value knob to set the password
[1]W then enter to adjustment parameter screen.hen password is 808,
[2]When password is 808, then enter to setting item selection screen.
Using up key /down key or
Set the knob to change the tension setting numerical values
Tension testing vale
Actual output value
Left tension detetector actual testing value
Right tension detetector actual testing value
Total actual testing value=Left tension detetector actual testing value+Left tension detetector actual testing value
Automatic control
Testing value: 24.9kg
Setting value: 25.0kg
Output value: 39.5%
Tension testing value
Left tension: 24.9kg
Right tension: 25.0kg
Tension: 49.9kg
Enter password
Password: 808
Set Esc
01.Initial radius
02.Coil thickness
03.Start&stop frequency
04.Tension alarm
▲
Using up key /down key or
Set the knob to change the tension setting numerical values
Target value: According to the diameter of the coil corresponding to different target operating tension,
Actual output value
Taper tension control
Target value: 18.0kg
Setting value: 25.0kg
Output value: 28.5%
Tip: When kg / N indicator light, LED display will show testing value.
Note: To prevent the controller parameters from misusing, please change the password to others after finished the parameters.
(3) Manual control mode
Using up key /down key or
Set the knob to change the tension setting numerical values
Tension testing vale
Manual control
Testing value 24.9kg
Setting value: 25.0kg
Output value: 39.5%
8
a. ccording to set value, volume diameter, taper coefficient calculated.
MODEL - STC858A
The following table have been classified based on function parameters.
9
3.3 Parameter Description
21
Tension measuring parameters: the following parameters affect tension measurement, when choosing automatic tension control, the following parameters must be set .
Adjustable parameters: the following parameters influence tension control accuracy, when choosing automatic tension control, the following parameters must set up correctly.
Function selection parameters: the basic parameters of the following parameters should be set according to the actual situation of the first.
22
23
24
25
Left error correction
Right error correction
Tension detector selection
Show unit
Signal range
-50.0 50.0kg～ 0.0kg
0.0kg
Left tension detector error correction, for small error correction,
-50.0 50.0kg～ Right tension sensor error correction, ditto
Left Tension detector selection
Right Tension detector selection
Left +right Tension detector selection
Left +right Tension detector selection
Select tension detector installation configuration
kg
Newton kg This parameter will affect all the parameters
±30 mV
±300 mV ±300 mV Teonsion detector signal range, was set based on
01
30
31
Display Filter
Zero Tension Calibration
Full-scale calibration
0.01 99.99～ 3.00 The larger the value, the more stable of the display
0.0kg 0.0kg Zero linear calibration
0.0 999.9kg～ 50.0kg Full-scale linear calibration
27 Winding Mode Winding, unwinding Unwinding Winding / unwinding set
Proportional band
Integration time
0.1 999.9kg～ 100.0kg
100.0%
0.1 10.0 seconds～1.0 Seconds
Normal mode
0.1 999.9kg～ 5.0kg
0.5 seconds
05
06
07 Dead space
When automatic operation, it will affect the
28
02
Feedback method
Output filter
Normal mode
Active send volume mode Positive control / anti-control options
0.1 100.0 ～ seconds This parameter limits the rate of change of output
20 Output range 0.0 100.0%～ Upper and lower output power controller
03 Taper factor 0.01 1.00～ 0.00
29 Second output
Synchronization Output
Axis cutting auxiliary output
Tension transmission output
Synchronous control output The second output type selection
Parameter NO.Parameter Name Adjusting range Factory default Description
Tension setting value limitation parameter
18 Setteing range 0.0 999.9kg～ 50.0kg Tension limitation setting of upper and lower
26 Communication address Controller Communications
12
13
14
15
Axis cutting output
Axis cutting time
Auxiliary output
Auxiliary time
0.0 100.0%～ 30%
0.1 25.0 ～ Second 2 Second
0.0 100.0%～ 0.0%
0.1 25.0 ～ Second 0.1 Second
Meaning of the parameters,
Axis cutting parameters: the following parameters affect the outputhe, when the systeim have the axis cutting function, then it should be set up correctly.
Communication parameter
32 Chinse/English Language selecting
33
34
Parameter Backup
Factory Reset
Recovery
backup Backup & recovery parameter
Recovery Restore factory settings, so the current settings will be lost
Tension alarm 0.0 999.9kg～ 0.0kg Runtime to alarm, when the axis switching and starting / stopping will not alarm
04
Additional function parameters
Chinse/English Chinse
For taper tension control, taper tension control
of the rate of change in tension.
if the error is too large then need to be re-calibrated tension
options based on the actual situation.
associated with the display unit.
tension sensor output signal range.
accuracy of the tension control.
see page 18: 4.2.5-axis switch.
MODEL - STC858A
10
Continued on Page Form
4.1 Tension testing
Chapter 4 Automatic tension controller
STC858A accept a variety of tension detector input signals, to make the appropriate jumper settings for different detectors:
[;1] Micro displacement special tension detector, the input signal range is 300mV, 5V power supply (such as the LS series, and mitsubishi tension sensor compatible)
4.1.1 Tension detector installation and wiring
Follow below steps to debug
[。1] Powering on after making sure the tension Controller were installed and wired properly.
[2] Ensure that the tension detector installation and wiring is correct, check and determine the tension detector signal is normal.
[3] To process program settings for the relevant parameters of tesnsion testing.
[4] To calibrate the zero and full-scale for the tension signal , and make sure the tension displayed normally,
[5] Through manual adjustment, operation to check the system, to confirm the tension displayed normally and actuating element is operating normally.
[6] If the above steps work properly, switching to automatic control mode, to adjust the parameters of the PI based on the operation,
Sw1 switch settings are as follows：5V
[2] Bridge strain-specific tension sensor, the input signal range is 30mV, 10V power supply:
Sw1 switch settings are as follows: 10V
08
09
10
11
Prepare output
Start time
Stop gain
Stop time
0.0 100.0%～ 0.0% The output value when the system starts
0.1 25.0 ～ seconds 0.1 seconds System start time
01 400%～ 100%
0.1 25.0 seconds～ 0.1 seconds System sopt time
Start and stop synchronization 0.1 100Hz～ 0Hz19
16
17
Acceleration factor
Deceleration factor
0.01 2.00～
1.0
0.01 2.00～ 1.00
Meaning of the parameters, see page 20: 4.2.6
Start / stop parameters: The following parameters affect the output when the system starts, it should be properly set
according to actual situation (for details see page 17: 4.2.4 System Startup and Shutdown)
The system through clinical testing the spindle speed to
automatically start/stop operation, When synchronous
start-stop at 0HZ, synchronous start-stop function closed.
Acceleration / deceleration control.
if the tension does not displayed normally, go back to step [2].
to ensure the system of tension running smoothly.
MODEL - STC858A
4.1.2 Related parameters of tension testing Settings
25.Tension signal range
30 mV±
300 mV±
23.Detector selection
Left tension controller
Right tension controller
Left+Right tension controller
24.Tension display unit
kg
Newton
▲▲
21.Left error correction
22.Rightt error correction
23.Tension controller selection
24.display unit
25.Signal range
▲
Set
▲
In order to measure the coil tension of tension controller correctly, it is necessary to set the relevant parameters of tension tesing correctlly:
1.Tension detector selection[23]
This controller can choose one or two tension detectors to work which based on tension detector installation conditions Settings.
2.Display unit[24]
STC858A can choose two units showing tension measuring value: "kg (kg)" and "N (Newton)"
3.Signal range[25]
The controller can choose two signals, ± 30mV and ± 300mV which depending on the installation of the detector selecting corresponding signal range.
If LS series tension detector was selected, the signal range [25] should be set to ± 300mV.
If SUP/ZC series tension detector was selected, the signal range [25] should be set to ± 30mV.
4.Left error correction [21] / right error correction [22]
When measured values occuring zero offset, if offset error is smaller, then to modity the detector error, and can revise the zero point via modifying,
When processing tension calibration, the correction value reset to 0.
5.Display filter[01]
。 Contrller with digital filtering algorithm which can remove the measurement signal interference and transition to make the measurements showing stable.
The larger the filter coefficients, the measurements will show more stable, but the reaction will turn to slow, usually set at 2.00.
21.Left tension error correction
OFST-L 0.0kg
Esc Confirm/exit
22. Right tension error correction
OFST-R 0.0kg
Esc Confirm/exit
Esc
With the up / down key or value set
With up/down key or value set knob
Selecting the parameters to be set, then pressing Set button to enter
11
and also the revised value can be added to tension displaying value. If offset error is bigger which should re-calibrate the tension controller.
knob to modify the parameter value,
then press the Esc key to save and exit.
MODEL - STC858A
[1] Before calibration, ensure that tension detector is wiring correctly, confirm the tension detector works properly, the tension signal
[2] Using a multimeter to measure the output signal of the detector with 300mV gear, it's about 0mV, when the detector was without
4.1.3 Tension calibration
(1) To move the cursor to zero tension calibration [30]
(2) Press Set key to start calibration
Press Esc key to exit calibration
(3) Display calibration screen, please wait a few seconds,
Purpose: to perform revision for the bearings and the detector roller.
Note: Zero tension calibration should be performed in condition of installing detector roller, but without loading coil.
(2) Zero tension calibration
In order to perform closed-loop tension control correctly, the tension must be accurate, must to perform the
(1) Note
12
30.Zero tension calibration
31.Full-scale calibration
33.Parameter back-up
Set/confirm Esc/exit
Calibrating, please wait. . .
Set
Set
Esc
Calibration completed
▲
32.Chinese/English
30.Zero tension calibration
calibration for the tension control, in this case, the well calibrated tension controller
precision. STC858A tension controller are adopted two linear calibration which calibration process is very simple.
will achieve the perfect
is within the selected range.
forcing. And the output signal will be changed, when the detector was with foring, but it can't exceed the maximum output signal of
the detector. For LS series tension detector which can't exceed 300mV, or the detector will be failure which need to replace,
install and calibrate again.
after entering parameters menu,
then press Set key to enter the calibration screen.
it will be returned back to parameter menu automatically
aftercalibration completed.
MODEL - STC858A
(3) Full-scale calibration
Tension detector
Tension detector
Thread a string through the roller centers
Hang known weight load W (kg)
Note: the weight of the load should
13
(2) Enter to parameter menu, move the cursor to a full-scale calibration [31]
Then press Setkey to enter to calibration screen
((3) Press▲ / ▼ keys or numeric values setting knob to change P2
(5) Display calibration screen, please wait a few seconds,
it will be returned back to parameter menu automatically
(6)
Till the tension display correctly, then enter to next adjustment.
P2= 50.0kg
Now executing
Set
Set
Esc
(1) Hang known wight W(kg) from the detector roller, refer to above drawing.
(4) Press Set key to execute the calibration,
31.Full-scale calibration
not be less than ½ span of the
tension detector.
30.Zero tension calibration
31.Full-scale calibration
33.Parameter back-up
▲
32.Chinese/English
Calibrating, please wait. . .
Calibration completed
Set/confirm Esc/exit
value to make it equal to the load weight.
Press Esc key to exit the calibration
.
after calibration completed.
Calibration completed, if the an error message appears,
check tension installation, tension detector signal,
set parameter and re-calibrate.
MODEL - STC858A
4.2 Adjustment operation
When tension was measured correctly, then enter to the automatic and manual operation mode of controller for adjustment.
4.2.1 Manual control
4.2.2 Automatic control
When the controller is in automatic control mode, press the AUTO / MAN key, MANUAL indicator light, the controller move to
As the output value changes, the tension measured values will be changed accordingly, coil achieves proper and stable tension,
When the controller switch to automatic control mode from manual control mode to , the controller will set the measured
Tension setting value is to achieve the target tension ffor coil during controlling. In automatic operation, the controller will
When there is an error of tension testing value appears , and fault code will display, then it can't be switched to automatic mode
Controller in stop condition, AUTO light blinking.
Controller output was controlled by output key, re-press this button, the output will be switched between on/off.
OUTPUT ON/OFF LED lights:allowed output;
OUTPUT ON/OFF LED off:Not allow output, LED display shows 0FF, output value is 0.0%.
Make MC1 connected, when perform automatic control
If MC1 switches off, the controller will be transferred to stop condition, then AUTO LED blinking,
When the synchronization start and stop [19] function starting, the system start / stop switch will
Manual control
Testing value: 24.9kg
Setting value: 25.0kg
Output value: 39.5%
Automatic control - constant tension mode screen Automatic Control - taper tension mode screen
OUTPUT
ON/OFF
Output on-off key and indicator lights
MC1
MCC
Start/stop on-off key
Tension actual testing value
Press▲ / ▼ keys or numeric
Actual output value
According to different reel diameter
Please observe the changes of measured value, when modifying the output value.
Press▲ / ▼ keys or numeric values setting knob to modify the output value.
14
firstly operate it with manual control mode, when manual operation works normally, coil achieves proper and stable tension,
then switch it to automatic control mode.
manual control mode, Press▲ / ▼ keys or numeric values setting knob to modify the output power value directly, modifying
range was limited by maximum output value [20]
then switch it to automatic control mode.
When the controller is in manual control mode, press the AUTO / MAN key, AUTO indicator light, the controller move to
automatic control mode, Press▲ / ▼ keys or numeric values setting knob to modify the tension setting value, modifying
range was limited by maximum setting value [20]
value as setting value then, achieved disturbance-free switching.
perform the calculation after adjustment output based on setting value, measured values and parameter proportional band [05],
the integration time [06], the static area [07] which to make the tension tends near to the actual setting value , to achieve the control effect.
even through pressing AUTO / MAN key.
Manual control
Testing value: 24.9kg
Setting value: 25.0kg
Output value: 39.5%
values setting knob to change
tension testing value.
Taper tension control
Target value: 18.0kg
Setting value: 25.0kg
Output value: 28.5%
Manual control
Testing value: 24.9kg
Setting value: 25.0kg
Output value: 39.5%
Manual control
Testing value: 24.9kg
Setting value: 25.0kg
Output value: 39.5%
Press▲ / ▼ keys or numeric
tension testing value.
values setting knob to change
Actual output value
corresponding to operation tension
target value was calculated based
on setting value, reel diameter,
taper coefficient.
the output preparing output value P.on.
not only controlled by the MC1, but also controlled by the spindle speed.
MODEL - STC858A
05.Proportional band
PROP= 150.0kg
Set/confirm Esc/exit
06.Integration time
INTT= 1.0 seconds
Set/confirm Esc/exit
07.static area
DB= 5.0kg
Set/confirm Esc/exit
4.2.3 Proportion integral parameter Settings
(1) Proportional band
(2) Integration time
(3) Static area
The larger the static area, the more stable the system, but it responses slowly.
In general, static area [07] to set the value as 0.5 to 1.0 times.
To revise the output is based on the proportion of deviation between tension setting value
The smaller the proportional band, the faster the system responses, but it's easy to
In general, the proportion band [05] set as 2 to 3 times of the tension.
When STC858A in automatic control mode, proportion, integral, static area parameter values influence the stability and control precision
Integration time is used to eliminate static error, setting range: 0.1 to 10.0 seconds.
The smaller the integration time, the speed , faster the responses but it's easy to
and resulting unstable to the system.
In general, the integration time [06] is set to 1.0 seconds.
LTC858A
Output Tension setting value
Deviation
Tension testing value
Tension
+
Unwinding roller
Powder brake
Control
calculate
Tension controller comparative with the deviation of tension setting
15
(4) Output filter coefficients
43.Output filter coefficients
FIL= 10.0 seconds
Set/confirm Esc/exit
Output filter coefficients can limit the rate of change of output, making
The larger the Coefficient, the slower the output changes, usually set as 10.0 seconds.
of system, such as tension control is unstable which need to adjust and set the appropriate proportion, integral and static area parameter
values.
detector
tension controller
value and tension measurement value, after calculated via the proportion
integral algorithm, adjust the output which make the tension of coil tended
to setting value an to achieve the goal of constant tension control.
Therefore, set proper parameter of proportion, integral, static area
is very important for the stability of the tension system.
and actual tension. setting range: 0.1~999.9。
oscillations and the system is unstable.
The larger the proportional band, the slower the system responses, the more stable of the system.
The larger the integration time, the slower the system responses, the system more stable.
oscillations
the output does not change rapidly, so as to avoid tension oscillation.
MODEL - STC858A
When the start-stop switch S1 connected, the system start running, the controller put into operation automatically , to perform constant tension
Start, stop of STC858 Tension Controller is controlled by the terminal MC1, MCC, MC1, MCC terminals connect to a switch which
When the synchronization start and stop [19] started, start / stop of the system will be not only controlled by switch S, but also
Using sart and stop synchronization function, a proximity switch must be installed on the spindle, the controller will monitor the
When the start-stop switch S1 connected, the operating frequency of spindle is larger than the frequency of start and stop[19],
When the start-stop switch S1 connected, the operating frequency of spindle is smaller than the frequency of start and stop[19],
In the automatic tension control system, generally short the MC1 and the MCC, the system will control start/stop of
(1) Start and stop control
MC4
MC4
MCC
MCC
Prepare output
4.2.4 System start and stop
24V
DI0
GND
NPN pulse signal
Detector roller pulse input wiring diagram
(2) Start-up process
(3) Stop process
(4) Prepare output selection
When controller is in condition of stopping, AUTO LED is blinking.
Prepare output of system is controlled by prepare output selection S4 .switch
When switch S4 is connected, the output valueP of stopping moment (the moment that MC1 ans MCC is disconnected)
When switch S4 is disconnected, the prepare output [08] which preset in the controller memory is prepare output.
Generally the prepare output switch S4 will be used in below mode:
1. When suspended machine, connecting to S4, using the output memory function to start form stopping output value.
2. When replacing material volume, disconnect the S4, to start operation from the output which preset in the controller
stop time stop time
Start & stop state
Start & stop state
Auto LED Auto LED
ON ON
Lighting Lighting
OFF OFF
Blinking Blinking
OFF OFF
Blinking Blinking
Control output Control output
stop output=P×G
stop output=P×G
P P
G:stop gain[10]
G:stop gain[10]
Prepare output[08]
Prepare
Prepare
P
Start/stop process - Prepare output selection switch connected Start/stop process - Prepare output selection switch disconnected
MC1
MC1
MCC
MCC
S1connecting
S1 shutdown
Start
Stop
S1
S1
S1:Start-stop switch
MC4
MCC
S4
S4 S4
16
switch (S1) is the system start -stop switch, connecting or shutdown of S1 switch will start or stop the tension system operation.
control by the operating frequency of the spindle.
operation frequency of the spindle .
start running, AUTO LED lights up.
stop running, AUTO LED blink.
the system automaticlly based on the operating frequency of detector roller.
tension close-loop control based on tension of setting, AUTO LED lights up.
During operation, at the moment of S1 start /stop switch is off, the controller will then get the output value P multiplied by the stop
gain stop [10] G as the moment output which making the operation speed of system decreased rapidly, meanwhile. stop the timer
starting timing, and automatic controlled during stop proccess, the controller will put into open-loop operation when approaching
to stop time, to output prepare output P.on, to generate prepare tension.
of the system is the prepare output.
selection switch S4
memory, then prepare output [08] will be the output value of corresponding initial diameter.
output output
MODEL - STC858A
When winding method [27] is unwinding, follow below steps to complete the axis switching process:
A ssuming A axis is running, then to connect axis switching, and then the output of controller will be output to B axis, rather than A axis,
At the same time, the auxiliary output [14] with in the auxiliary time [15] of preset to output current to A axis which to stop A axis running quickly.
If the axis switching switch to disconnection state from connection state, namely, switch to A axis in waiting from B axis in
(1) Axis switching control
(2) Unwinding axis switching process
4.2.5 Axis switching
axis switching switch axis switching switch
MC2 MC2
MCC MCC
When the system using dual-axis (A, B axis) to run in turn, need to switch the reel when the material in unwinding reel is near to
The axis swithcing of STC858A tension controller is controlled by terminals MC2, MCC when MC2, MCC terminals
Switch off: A shaft running Switch close up: B shaft running
PA, NAoutput
Tension controller
A axis powder brake
B axis powder brake
Coating roller
Coating solution
STC858A Tension controller
PB, NBoutput
dual-axis switching
MC2
MCC
LTC858
sTe ion Co ntro llern
UO T
mm
%
k /gN
UTO TPU
/ON OFF
N LMA UA
AUTO
COM
LO K
C
A ML
UO TA OU BT
AUTO
MAN
Set Esc
17
(3) Rewinding axis switching process
When winding method [27] is rewinding, follow below steps to complete the axis switching process:
If the axis switching switch to short state from disconnection state, namely, switch to A axis in waiting from B axis in
completed. or when the material in the rewinding reel is almost full.。
switch
switch is on/off which means the axis switching switch of the system will be on/off. When the axis switching switch
is off, then A axis runs; when axis switching switch is shorted, then B axis runs.
at this time, the axis switching output [12] of output preset, meanwhile, axis switching timer start to timing, when reach to the end of axis
switching time [13], the controller put into operation, to perform the constant tension closed-loop control based on setting tension.
running which the control process is the same, just need to interchange A axis and B axis as above.
Assuming A axis is running, then to connect axis switching, and then auxiliary output[14] output to B axis which to make B axis
running, meanwhile auxiliary timer start timing, when auxiliary time reach the end, and then the output of controller will be output
to B axis, rather than A axis, at this time, the axis switching output [12], mean while the axis switching timer start timing, when reach
the end axis switching time [13], the controller put into operation automatically, to perform the constant tension closed-loop control
based on setting tension.
running which the control process is the same, just need to interchange A axis and B axis as above.
MODEL - STC858A
Table of contents
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