AUTOK TC818 User manual

TC818
TENSION CONTROLLER
INSTRUCTION MANUAL(V4.00)

Table of Contents
Note: This manual is applicable to software version 4.00 or later.
1 Introduction .......................................................................... 1
1.1 Overview .......................................................................... 1
1.2 Features ........................................................................... 1
1.3 Order code ....................................................................... 2
1.4 User interface ................................................................... 2
2 Mounting and electrical wiring .............................................. 4
2.1 Dimension ........................................................................ 4
2.2 Mounting .......................................................................... 4
2.3 Electrical connection ........................................................ 5
3 Menu operation .................................................................... 7
3.1 Overview of operation ...................................................... 7
3.2 Introduction to major screens .......................................... 8
4.2 Operation ....................................................................... 15
4.3 Taper tension control ...................................................... 23
5 Diameter Tension Control ................................................... 24
5.1 Introduction ..................................................................... 24
5.2 Roll radius monitoring ..................................................... 25
5.3 Basic operations ............................................................. 27
5.4 Constant tension control ................................................. 28
5.5 Taper tension control ...................................................... 29
5.6 Program tension control ................................................. 30
6 Additional functions ............................................................ 32
7 Serial communications ........................................................ 33
8 Appendices .......................................................................... 37
8.1 Parameters screen ......................................................... 37
8.2 Troubleshooting .............................................................. 38
8.3 Technical specifications .................................................. 39
3.3 Parameter list .................................................................. 9
4 Automatic tension control ................................................... 11
4.1 Tension measurement .................................................... 11
6.1 Language ....................................................................... 32
6.2 Parameters backup ........................................................ 32
6.3 About infos ..................................................................... 32

1.1 Overview
The TC818 tension controller is part of a closed-loop tension control system with tension sensor feedback.
The controller continuously controls the web tension to the setting tension value and display the true web
tension on an LCD screen. The screen will display the tension applied to each tension sensor separately.
The controller has a graphic LCD display
0~24V/4A output, the
controller can also outputs 0~5V, -5V~+5V, this can drive the inverter, servo motor or other power units.
The TC818 can be used in papermaking, printing, packaging, textile, print and dyeing industries, etc.
Chapter 4 covers automatic tension control and the Chapter 5 covers diameter tension control.
, Chinese and English menu selectable, the user interface is friendly
and easy to use.
The controller can drive the magnetic powder brake/clutch directly with its built-in
Powder brake
Powder brake
Proximity switch
Automatic Tension Control Radius Tension Control
ad cell
Lo
● 128x96 graphic LCD, Chinese and English ● Diameter tension control.
menu, easy to use. ● RS232/RS485 communication interface, the
● Full digital circuits, no potentiometer. controller can be used to form Distributed
● Control System(DCS) with PLC and PC.
●
● input, can be used ● Two reel exchange.
with several kinds of tension sensors: ● Acceleration and deceleration operation.
1. Micro-displacement based tension sensor ● Automatic/Manual tension control.
(signal: 200mV, power supply: 5V DC) ● Parameters protection by password, avoid
2. Strain gauge based tension sensor inadvertent modification.
(signal: 20mV, power supply: 10V DC) ●
3. 2K potentiometer in dancer control system
● Taper tension control.
High and stable measurement and easy
tension calibration. Build-in PI algorithm.
Single/Dual tension signal
Wide range input switching power
supply(92~264V AC).
1.2 Features
1 Introduction
1
Tension Controller TC818
TC818
TC818

1.4 User interface
TC818
Tension Controller
OUT
mm
%
kg/N
OUTPUT
ON /O FF
MANUAL
AUTO
COM
LOCK
ALM
OUTA OUTB
AUTO
MAN
Set Esc
󰾡AUTOK
1. LCD display22. 7-seg display
2. Lock indicator
3. Lock key
19. Output LED
18. Output ON/FF LED
17. Output ON/OFF
switch
15. , Increase key
16. , Decrease key
13. Set, Confirm
21. Content LED
14. Esc, Escape
20. LED display
selector
8. Digital knob
4. Automatic mode LED
6. Manual mode LED
7. Auto/Manual switch
5. Door open screw
9. OUTA, Reel A output indicator
10. OUTB, Reel B output indicator
11. ALM, Tension alarm indicator
12. COM, Communication indicator
1.3 Order code
Main Output Aux Output1 Aux Output2 Comms Version
2
(1) (2) (4) (5)
Code
0
RS232
RS485
None
RS232 interface, 3 wires
RS485 interface, 2 wires
Meaning
(4) Communication
Code
V1.00
V2.00
V3.00+
Radius tension controller
Automatic tension controller
Automatic and Radius tension
controller
Meaning
(5) Software Version
24V
36V
0
Code
24V/4A, drive magnetic
powder brake/clutch
36V/3A, drive magnetic
powder brake/clutch
None
Meaning
(1) Main Output
(3)
Code examples:
(1) TC818-36V/0/0/0-V3.00 designates the controller with
(2) TC818-24V/V05/V05/0-V4.00 designates the controller with 24V/4A main output and with 0~ 5V auxiliary output
1 and auxiliary output 2, drive torque motor driver or inverter, software version is V4.00.
36V/3A main output which can drive magnetic powder
brake/clutch, software version V3.00.
Code
None
0~5V DC
-5V ~ +5V DC
Meaning
0
V05
V05PN
(2) Auxiliary Output 1
0~10V DC
4~20mA DC
V10
A420
(3) Auxiliary Output 2
Tension Controller TC818
TC818 - - / / /

1. Set/Esc
Set: Enter the next menu screen or confirm operation.
Esc: Back to previous menu screen or “Confirm/Exit” after finishing the setting of the value.
2. AUTO/MAN switch and indicators
The automatic mode and manual mode can be switched by pressing this key.
In automatic mode, the indicator AUTO will be lit, at this time, the setting tension can be altered by
pressing the Inc/Dec key or turning the digital knob.
The flash of AUTO LED indicates that the controller is in stopping mode.
In manual mode, the indicator MAN will be lit, at this time, the output can be altered using the Inc/Dec key
or turning the digital knob.
While switching the controller from manual mode to automatic mode, the measured tension before
switching will be used as the setting tension for automatic control, this makes the smooth transition.
If the measured tension is incorrect and the error code appears, the controller will switch to manual mode
automatically, in this case, the controller can not be switched to automatic mode.
3. OUTPUT ON/OFF switch and Indicator
The output of Reel-A and Reel-B can be turned ON and OFF by pressing the 'OUTPUT ON/OFF' switch.
When the indicator is lit, output is 'ON' otherwise the output is 'OFF'.
4. LED display selector and Content LED
The type of contents displayed on the 7-seg display is changed every time the LED Display Selector is pressed.
The type of contents displayed is indicated by the Content LED provided on the left side of the 7-seg display:
kg/N: measured tension in kg or Newton
% : output
mm : radius in mm
5. LOCK key and Indicator
This key is used to lock/unlock the keypad except the LED display selector.
Lock indicator is on: keypad locked.
Lock indicator is off: keypad unlocked.
If set Function[29] to Radius control, in "Enter PWD" screen, the reel radius can be initialized to initial
radius R0. In this case, if Ctrl Mode[30] = Program Ctrl, the "Radius-Output" parameter list can be revealed
using the LOCK key, at this time, the user can alter the value of the parameters.
6. OUT: Output indicator
The brightness of this green LED indicates the magnitude of the output, the brighter LED, the greater
output. The LED will be off when the output is zero.
7. OUTA: Reel A output indicator
This LED indicates the output states of Reel A, it is lit when output of Reel A is ON.
8. OUTB: Reel B output indicator
This LED indicates the output states of Reel B, it is lit when output of Reel B is ON.
9. ALM: Tension alarm indicator
According to the setting of Alarm Mode[44] and Alarm Value[04], this red indicator ALM will be lit when
the alarm condition appears. At the same time, the relay ZT will be 'ON' to output an alarm signal. The alarm
function does not act in Run/Stop and reel exchange progress. See 4.2.9 Alarm for details.
10. COM: Communication indicator
The indicator COM flashes when the controller is in active communication with a host computer.
3
Tension Controller TC818

TC818
Tension Controller
OUT
mm
%
kg/N
OUTPUT
ON /OF F
MANUAL
AUTO
COM
LOCK
ALMOUTA OUTB
AUTO
MAN
Set Esc
AUTOK
4-M4
80+
-
0.5
232
+
-
0.5
150+
-
0.5
245
228
16.5 140
147
154
60
60
2.1 Dimensions
2.2 Mounting
256
168
TC818
Tension Controller
OUT
mm
%
kg/N
OUTPUT
ON/O FF
MANUAL
AUTO
COM
LOCK
ALMOUTA OUTB
AUTO
MAN
Set Esc
AUTOK
172.5
2~4mm
140
2 Mounting and electrical wiring
4
unit: mm
244+
-
0.5
The controller can be installed on floor, wall or panel.
Installed on floor Installed on wall Installed on panel
4-M4*12
Mounting screw
Screw holes for mounting
on floor and wall Panel mounting cut-out
Tension Controller TC818

2.3 Electrical connection
Terminal block 1: Terminal block 2:
2.3.2 Connection diagram
NB
PB
NA
PA
Reel A pulse*
Reel B pulse*
Tension sensing
roller pulse*
RS485 RS232
Power Supply
(160~240VAC)
24V
DI0
DIA
DIB
GND
MC4
MC6
MC3
MC5
MC2
MC1
MCC TRG GND
TR- RXD
TR+ TXD
ZTC
ZT
EAP
EAN
SA
Run/Stop
SN
PSL
PSN
REDL
GRL
WHL
GRR
WHR
BLKL
REDR
BLKR
Tension
Sensor
Left
power+(red)
signal+(green)
signal-(white)
power-(black)
ZT
power+(red)
signal+(green)
signal-(white)
power-(black) +
-
+
-
*NPN pulse
} }
}
}
}
2.3.1 Connection notes
5
Tension
Sensor
Right
[1] In order to avoid electrical noise to the input signal, the signal line should be away from the power line.
[2] If the AC power supply is connected to the I/O terminals or DC supply terminals, the tension controller will
be burn out.
[3] Connect the tension sensor according to the wiring diagram, pay more attention to the wiring of tension
sensor if two tension sensors are connected otherwise the measurement value will be incorrect.
[4] When one tension sensor is used, make sure to short-circuit the unused tension signal terminals.
Tension alarm output
Aux. output 1(drive Reel A power unit)
(0~5V/0~10V/4~20mA/0~20mA)
Aux. output 2(drive Reel B power unit)
(0~5V/0~10V/4~20mA/0~20mA)
Acceleration button
Deceleration button
Output ON/OFF button
Start output selector
Reel exchange
Note:
The color of the wire is optional, please
refer to the sensor's manual for
appropriate connection.
Tension Controller TC818
2K pot.
GRL
WHL
Reel A
Clutch/Brake
Reel B
Clutch/Brake
Main output A
24V/4A
Main output B
24V/4A

2.3.3 Terminals description
Terminal block 1:
Terminal block 2:
SN
1
2
3
4
5
6
7
8
10
9
11
12
13
Terminal
PSL, PSN
ZT, ZTC
PA NA,
PB, NB
MCC
MC1
MC2
MC3
MC5
MC4
MC6
+24V, GND
DI0
Specification Comments
IN
OUT
OUT
OUT
IN
IN
IN
IN
IN
IN
IN
IN
OUT
85~264V AC, 50/60 Hz
Relay, 3A/250VAC, NO
I/O
Controller Power supply
Tension alarm output
drive Reel A magnetic powder clutch/brake
drive Reel B magnetic powder clutch/brake
External switch/button input common terminal
Run/Stop
Reel exchange
Acceleration button
Deceleration button
Start output selection
External OUTPUT ON/OFF button
Power supply for proximity switch/Encoder
Main roller proximity switch pulse inputMax frequency 15kHz
24V/4A or 36V/3A
24V/4A or 36V/3A
SN
1
2
3
4
5
6
7
8
9
10
11
12
13
Terminal
DIA
DIB
GRL
WHL
REDL
BLKL
GRR
WHR
REDR
BLKR
SA SN,
EAP, EAN
TR+,TR-,TRG
Specification Comments
IN
IN
IN
IN
OUT
OUT
IN
IN
OUT
OUT
OUT
OUT
OUT
Max frequency 15kHz
I/O
Reel A proximity switch pulse input
Reel B proximity switch pulse input
Left tension sensor signal+
Left tension sensor signal-
Left tension sensor power supply+
Left tension sensor power supply-
Right tension sensor signal+
Right tension sensor signal-
Right tension sensor power supply+
Right tension sensor power supply-
Sync. output, 0~5V(drive Reel A power unit)
Output 2, 0~5V(drive Reel B power unit)
RS232/RS485 communication interface
RS232, RS485
0~200mV or
0~20mV or
2K pot.
14 +5V,0V OUT Auxiliary power supply
5V or
10V
0~200mV or
0~20mV
5V or
10V
0~20mA or 0~5V
0~20mA or 0~5V
6
24V DC
Left
Right
Tension Controller TC818

3.1 Overview of operation
AUTO
MAN
Set
Set
Esc
Set Set
Esc Esc
Password: 808
Password: 818
Set
Operation parameters menu
Complete setup menu
Esc Esc
Auto Monitor
PV.: 24.9kg
SV.: 25.0kg
Out: 39.5%
Man Monitor
PV.: 24.9kg
SV.: 25.0kg
Out: 39.5%
Tension
Left: 24.9kg
Right: 25.0kg
Total: 49.9kg
Enter PWD
Password: 808
Set:OK. Esc:Exit
3 Menu operation
Power ON
TC818张力控制器
软 件 版 本: ver2.20
󰾡
Select the menu item
with the knob, press
Set key to enter
parameter setting
screen
01.Init Radius
02.Thickness
03.Start Freq
04.Alarm Value
05.Prop. Band
06.Inte. Time
07.Dead Band
08.StartOutput
09.Start Gain
10.Start Time
11.Stop Gain
12.Stop Time
13.Exch. Out
14.Exch. Time
15.Aux. Time
16.Inc Coeff.
17.Dec Coeff.
中文
27.Addr
28.Baud Rate
29.Function
30.Ctrl Mode
31.Taper t1
32.Count Mode
33.Max Radius
34.Min Radius
35.Radius R0
36.Pulse N1
37.Pulse N2
38.Calc Cycle
39.Torque
40.Wind Mode
41.Action Mode
42.Sync Mode
43.OUT2 Mode
18.Max SetVal 44.Alarm Mode
19.Min SetVal 45.OUTA SIGNAL
20.Max Output 46.OUTB SIGNAL
21.Min Output 47.In Filter
22.Left Offset 48.Zero cali.
23.RightOffset 49.Span Cali.
24.Sensor 50.English
25.Unit 51.Backup
26.Signal 52.About
▲
01.Init Radius
02.Thickness
03.Start Freq
04.Alarm Value
05.Prop. Band
06.Inte. Time
07.Dead Band
08.StartOutput
09.Start Gain
10.Start Time
11.Stop Gain
12.Stop Time
13.Exch. Out
14.Exch. Time
15.Aux. Time
16.Inc Coeff.
17.Dec Coeff.
▲
7
After powered on, the controller
will return to the state before
shutting down.
Tension Controller TC818

3.2 Introduction to major screens
(1) Automatic tension control: constant tension
(2) Automatic tension control: taper tension
(4) Tension monitor
(5) Password
(6) Parameters menu
Select the parameter using the Inc/Dec key or the knob
Press Set to enter the parameter screen
Press Esc to Exit
Change the password by pressing the Inc/Dec key or turning the digital knob
[1] Password=808, enter the operation parameter menu
[2] Password=818, enter the complete setup parameter menu
Alter the setting tension using the Inc/Dec key or digital knob
Measured tension
Output
Measured tension of the left sensor
Measured tension of the right sensor
Total tension = Left + Right
Auto Monitor
PV.: 24.9kg
SV.: 25.0kg
Out: 39.5 %
Tension
Left: 24.9kg
Right: 25.0kg
Sum: 49.9kg
Enter PWD
Password: 808
Set:OK. Esc:Exit
01.Init Radius
02.Thickness
03.Start Freq
04.Alarm Value
▲
Alter setting tension using the Inc/Dec key or knob
Target tension:
This value is calculated with the setting tension, radius and taper coefficient t1.
Output
Taper Tension
SP.: 18.0kg
SV.: 25.0kg
OUT: 28.5%
Note: The measured tension can be viewed in the LED display when the kg/N indicator is lit.
Note: In order to void inadvertent modification, change the password other than 808 after configuration.
(3) Manual tension control
Alter the output using the Inc/Dec key or knob
Measured tension
Man Monitor
PV.: 24.9kg
SV.: 25.0kg
Out: 39.5 %
8
Tension Controller TC818

3.3 Parameter list
Tension Controller TC818
9
22
Tension Measurement: Must be configured properly when Function[29]=Auto control
Radius Measurement: Must be configured when using Radius control or taper tension control
Regulation: These parameters affect the control precision, must be set properly when Function[29]=Auto control
Function Setting: The essential parameters, set prior
23
24
25
26
Left Offset
RightOffset
Sensor
Unit
Signal
-50.0~50.0kg 0.0kg
0.0kg
Left sensor error compensation for small error
(for big error, re-calibrate the sensor)
-50.0~50.0kg Right sensor error compensation
Left
Right
Left and Right
Left and Right Tension sensor configuration, set according
to the mounting
kg
Nkg All items which use units will be changed accordingly
±30 mV
±300 mV ±30 mV Signal range of the tension sensor, set
accordingly
47
48
49
In Filter
Zero Cali.
Span Cali.
0.01~99.99 3.00 The larger value, the smoother readout
0.0kg 0.0kg Zero calibration
0.0~999.9kg 50.0kg Span calibration
33
33
34
35
36
Count Mode
Max Radius
Min Radius
Radius R0
Pulse N1
Thick Sum
Ratio Thick Sum The method of measurement of the radius
10~999mm 500mm The maximum radius(upper limit of the radius)
10~999mm 40mm The minimum radius(lower limit of the radius)
10~999mm 50mm Radius of main roller(needed by ratio method)
01~1000 01 Number of pulse/r, main roller
37
38
39
40
Pulse N2
Calc Cycle
Torque
Wind Mode
01~1000 01 Number of pulse/r, material roller
01~1000 20 When the number of pulses counts up to this
value, the radius will be calculated
05~999Nm 50Nm The rated torque of the powder brake/clutch
Wind, Unwind Unwind Setting of rewind and unwind
01
02
Init Radius
Thickness
40-500mm 50mm The initial radius of the roller
0.001~1.000mm 0.020mm The thickness of the web
Prop. Band
Inte. Time
0.1~999.9kg 200.0kg
100.0%
0.0%
0.1~10.0S 1.0S
Reverse Ctrl
0.1~999.9kg 8.0kg
05
06
07 Dead Band
Affects the control precision in automatic
tension control systems
41 Action Mode Reverse Ctrl
Direct Ctrl Direct/Reverse control
20
21
Max Output
Min Output
0.0~100.0%
0.0~50.0%
The upper limit of the output
The lower limit of the output
29
30
31
Function
Ctrl Mode
Taper t1
Auto control
Radius control Automatic tension control and radius tension control
Constant ctrl
Taper tension
Program ctrl
Constant ctrl Control mode
0.01~1.00 1.00 Used in taper tension control
Auto control
43 OUT2 Mode
AUX OUTPUT
Sync OUTPUT
PV OUTPUT
Sync OUTPUT Type of Output 2
SN Parameter Adjustable Range Default Description
The table below divided the parameters into several categories by the functions.

Tension Controller TC818
10
27
28
Addr
Baudrate
0.0~9.9 0.0 Address of Instruments
4800,9600,19.2k bps 4800 bps Baud rate
50 中文English 中文
English 中文 Language
51
52
Backup
About
Restore?
Backup? Prameters backup and restore
Copyright information and URL
Alarm Value 0.0~999.9kg 0.0kg Does not work during reel exch., Start, Stop04
13
14
15
Exch. Out
Exch. Time
Aux. time
0.0~100.0% 0.0%
0.1~25.0S 0.1S
0.1~25.0S 0.1S
See 4.2.4 Reel exchange for details
08
09
10
11
12
Start Output
Start Gain
Start Time
Stop Gain
Stop Time
0.0~100.0%
50~200%
0.0%
100%
The output when system starts
0.1~25.0S 0.1S Starting time of system
01~400% 100%
0.1~25.0S 0.1S Stopping time of system
Start Freq 1~100Hz 01Hz
The speed of the main roller.
If Sync. Mode[42]=Enable, the system will
start/stop automatically by monitoring the
speed of the main roller
03
42 Sync Mode Disable
Enable Disable
If enabled, the system will start/stop
automatically according to the speed of the
main roller
16
17
Inc Coeff.
Dec Coeff.
0.01~2.00 1.20
0.01~2.00 1.00 see 4.2.5 Acceleration and Deceleration
Start/Stop: The outputs and timing in start/stop process (see )4.2.3 Run and stop operation
Reel Exchange: The outputs and timing in reel exchange process
Communication
Additional Functions
Limit of Setting Value
18
19
Max SetVal
Min SetVal
0.0~999.9kg 50.0kg The maximum setting value (upper limit)
0.0~999.9kg 0.0kg The minimum setting value (lower limit)
SN Parameter Adjustable Range Default Description
(Continued)

4 Automatic tension control
4.1.1 Tension sensor connections
4.1 Tension measurement
[1] Assure that the mounting and connection of the tension controller is completed and correct, and switch on
the power.
[2] Assure that the mounting and connection of the tension sensor is correct, check the output signal of the
tension sensor.
[3] Set the tension measurement related parameters to proper value.
[4] Make zero and span calibration and check whether the display of the measured tension is correct, if not,
go to step [2].
[5] Test the tension measurement and driving system in manual operation mode.
[6] Switch to automatic mode, set proper value for operation parameters to get the stable control of the web
tension.
GRR
WHR
REDR
BLKR
Right
Tension
Sensor
power+(red)
signal+(green)
signal-(white)
power-(black)
REDL
GRL
WHL
BLKL
power+(red)
signal+(green)
signal-(white)
power-(black)
Jumper settings Tension sensor connections
Jumper storage position
Left
Tension
Sensor
Note:
The color of the wire is optional, please
refer to the sensor's manual for proper
connection.
The controller may be used with micro-displacement based tension sensor and strain gauge based tension
sensor. The jumpers JP7, JP8 and J8 must be in the proper position for correct measurement.
1. Using micro-displacment based tension sensor,
The signal range is 200mV, powered by 5V DC.
Please short-circuit jumpers JP7, JP8, jump J8 to +5V.
2. Using strain gauge based tension sensor, e.g. the The signal
range is 20mV, powered by 10V DC.
Please open jumpers JP7, JP8, jump J8 to +10V.
3. In dancer control systems(using 2K Ohm potentiometer), please short-circuit jumpers L1 (provides
constant current source for pot.), JP7 and JP8.
e.g. the LX series tension sensor(compatible with the Mitsubishi
tension sensor).
SUP and the CTS/HTS series tension sensors.
Please debug by stepping through the following steps:
Tension Controller TC818
11
JP7 JP8
L1 L2
J8
+5V
R1
R2 R4
R3
+10V
2K Potentiometer
GRL
WHL

4.1.2 Setting of measurement related parameters
26.Signal Range
±30 mV
±300 mV
24.Sensor Select
Left
Right
Left and Right
25.Unit Select
kg
N
▲ ▲
22.Left Offset
23.RightOffset
24.Sensor
25.Unit
26.Signal
▲
Set
▲
In order to get the precise measurement of the web tension, the measurement related parameters must be set properly:
1. Sensor[24]
2. Unit[25]
3. Signal[26]
For LX series tension sensor, select
4. Left Offset[22]/RightOffset[23]
The measured tension will drift sometimes, if the drift error is small, the measured tension can be corrected by adding an
offset value. But if the drift error is big, the re-calibration of the controller is necessary.
Note that the left and right offset will be reset to 0 after calibration.
5. In Filter[47]
The controller has a built-in digital filter algorithm, it can cancel the interference and jump of the input signal and make
the display of the tension stable.
The greater filter coefficient, the more stable of display of tension but slow response, generally set to 2.00.
The controller can be used with one or two tension sensors, please make the selection according to the number of the
mounted sensors.
In dancer control systems, only one pivot point sensor are needed(connect to GRL and WHL), set to Left.
The tension can be displayed in Newtons or Kilograms. Select an unit system, all items which use units will be changed
accordingly.
The controller can be used with two input signal range:±30mV or±300mV, select the proper range according to the
sensor.
±300mV.
±30mV.
In dancer control systems(with a 2K Ohm pot.), select ±300mV.
Sensor[24]
For SUP/CTS/HTS series tension sensor, select
22.Left Offset
OFST-L 0.0kg
Esc:Confirm/Exit
23.Right Offset
OFST-R 0.0kg
Esc:Confirm/Exit
Esc
Alter the value using the
Inc/Dec key or digital knob
Press Esc to Confirm and Exit
Select parameter using the digital knob or Inc/Dec key
Press Set to enter
Tension Controller TC818
12

[1] Before calibrating, ensure the connection of the sensor is correct and jumpers JP7, JP8, J8, L1 and L2
have been set corresponding to the tension sensor.
[2] For LX series tension sensor, please short-circuit jumpers JP7 and JP8, jump J8 to +5V and set
Signal[26] to ±300 mV.
26] to ±30 mV.
[4] In dancer control systems(using 2K Ohm potentiometer), please short-circuit jumpers L1, JP7 and JP8
and set Signal[26] to ±300 mV.
[5] The output signal of the tension sensor can be tested using a multimeter, before testing, please switch the
multimeter to the 200mV position.The output signal should be about 0mV when there is no load applied to
the tension sensor.
While applied some force to the tension sensor, the readout of the multimeter will be changed: The bigger
force, the stronger signal, but it won’t exceed the max output range of the tension sensor, the output signal of
LX series tension sensor won’t exceed 200mV, for SUP/CTS/HTS series tension sensor, the upper limit is
20mV, if the measured signal exceeds the upper limit, the tension sensor may be damaged, please replace
new sensor and reinstall then re-calibrate.
[3] For SUP/CTS/HTS series tension sensor, please open jumpers JP7 and JP8, jump J8 to +10V and set
Signal[
4.1.3 Calibrate tension
(1) Scroll the cursor to Zero Cali.[48]
Press Set to show the calibrate screen
(2) Press Set key to start calibrating
Press Esc to Exit
(3) Calibrating, please wait.
returns to the parameter menu automatically
Upon calibration completed, the controller
48.Zero Cali.
49.Span Cali.
50.English中文
51.Backup
48.Zero Cali.
P1= 0.0kg
Do?
Set:do Esc:Exit
48.Zero cali.
Calibrating...
Pls wait 5 Sec.
4.1.3.2 Zero Calibration
Set
Set
Esc
Calibration Completed
▲
In order to implement the closed loop tension control system, the tension controller must be calibrated after
installation, and only the proper calibrated controller can get the desirous measurement precision. The
controller uses two-points linear calibration method, the process is very easy.
4.1.3.1 Calibration notes
13
Purpose: To compensate for the sensing roller weight and for any of the other analog zero offset voltages.
Note: The zero calibration must be performed with the weight of the tension sense roller and without
material.
In dancer control systems, adjust the dancer roller to the lowest position.
Tension Controller TC818

(2) Scroll the cursor to Span Cali.[49]
Press Set to show the calibrate screen
until the value equals to the known weight W
(3) Alter the value of P2 using the ▲/▼ key or the digital knob
(5) Calibrating..., please wait.
Upon completed, the controller
returns to the parameter menu automatically
calibration
(6) If the displayed tension is incorrect after calibration,
please check the mounting and output signal of the sensor
and the related parameter settings and then re-calibrate.
Until the display of the measured tension is correct.
49.Span Cali
P2= 50.0kg
Do?
Set:do Esc:Exit
49.Span Cali
Calibrating...
Pls wait 5 Sec.
48.Zero cali.
49.Span Cali.
50.English中文
51.Backup
4.1.3.3 Span Calibration
Set
Set
Esc
Calibration Completed
▲
(4) Press Set to start, Esc to exit.
14
Stretch a string in the
center of the roller.
Tension Sensor
Tension Sensor
weight
Suspend weight W kg
Note: The weight must be equal to or
greater than the ½ full-scale of the
tension sensor’s measurement range.
After calibrating, return to the control screen and verify that the display shows zero when no tension is being
measured and that the display shows the correct tension value when the weight is applied.
The controller will calibrate both tension sensor
simultaneously. The string must be in the exact center of
the web path so that each sensor is equally loaded.
Tension Controller TC818
Lowest position
(calibrate 0)
Calibration of dancer control system
Pivot point sensor
Highest position
(calibrate 100)
(1) Suspend a known weight on the tension sensing roller,
see the figure above.
(In dancer control systems, adjust the dancer roller to the
highest position)

15
4.2 Operation
4.2.1 Manual operation
4.2.2 Automatic operation
In manual mode, the indicator MAN will be lit, the output can be altered using the Inc/Dec key or turning the digital knob,
the output is limited by Max Output[18] and Min Output[19].
The measured tension will be changed during the altering of the output, after the measured tension of the web is stable,
the controller is ready to be switched to the automatic operation mode. To switch to automatic mode, just press the
AUTO/MAN key.
The control output is controlled by the OUTPUT ON/OFF switch, press this key,
the output switches between ON and OFF.
OUTPUT ON/OFF indicator is lit: Control output is ON;
OUTPUT ON/OFF indicator is off: Control output is OFF, output becomes 0.
Note that the control output also is controlled by the OUTPUT ON/OFF button(MC6 and
MCC), repeatedly press this key, the output switches between ON and OFF.
repeatedly
Please close switch in automatic control mode.
If MC1 is open, controller will turn into stopping mode, AUTO indicator flashes, the output will
become P.on.
Note that if the Sync. Mode[42] function is enabled, the Run/Stop of the system will not only
controlled by MC1, but also by the speed of tension sensing roller.
MC1
Auto Monitor
PV.: 24.9kg
SV.: 25.0kg
Out: 39.5%
Taper Tension
SP.: 18.0kg
SV.: 25.0kg
OUT: 28.5%
Man Monitor
PV.: 24.9kg
SV.: 25.0kg
Out: 39.5%
Automatic mode: constant tension control Automatic mode: taper tension control
OUTPUT ON/OFF switch
and Indicator
Run/Stop Switch
Measured tension
Alter the setting tension using the
digital knob or Inc/Dec key
Output
Target tension
Output
Alter the setting tension using
the digital knob or Inc/Dec
Observe the change of the measured tension while altering the output
Alter the output using the digital knob or Inc/Dec key
After finishing the tension calibration and the measured tension is right, the controller can be tested with manual
operation and automatic operation. First use manual operation, if the tension system works well(get the stable tension),
the controller can be switched to automatic mode to perform closed loop tension control.
In automatic mode, the indicator AUTO will be lit, the setting tension can be altered using the digital knob or the Inc/Dec
keys. The adjustable range is limited by the Max Setvalue[18] and Min Setvalue[19].
The setting tension refers to the process of control, the value expected to reach the goal of tension. In automatic mode,
the controller compares the measured tension with the desired tension, called the 'setting tension', and regulates the
output power to make them the same.
The measured tension is referred to as the Process Value, or 'PV' for short while the setting tension is referred to as the
Setting Value, or 'SV' for short.
If the tension measurement fails, the error message will appear and the controller will be automatically switched to the
manual mode, the automatic/manual mode can not be switched at this time.
Note that in stopping mode, the AUTO LED flashes.
To switch to manual mode, just press the AUTO/MAN key.
While switching the controller from manual mode to automatic mode, the measured tension before switching will be used
as the setting tension for automatic control, this makes the smooth transition. So it’s better to operate the system in
manual mode first, after the web tension gets stable the system should be switched to automatic mode.
Tension Controller TC818
OUTPUT
ON /O FF
MC1
MCC
MC6
MCC
OUTPUT ON/OFF button

16
Tension Controller TC818
Once switch S1 on, the controller will start the automatic control to the tension system, the controller performs the closed
loop control, LED AUTO will be it.
When the system halts, switch S1 on, start output*Start Gain[09] will be the output value, this speeds up the tension
system, at the same time, the start timer starts, when the Start Time[10] times up, the controller will enter the closed
loop control mode.
The start and stop operation is controlled by the Start/Stop Switch(S1) connected to MC1 and MCC.
If the Sync. Mode[42] function is enabled, the start and stop of the tension system is not only controlled by the
Start/Stop Switch but also be controlled by the speed of main roller. To use the Sync start/stop function, a proximity
switch or encoder must be mounted on the main roller to monitor the running revolution.(i.e. the running frequency)
When S1 is ON,if the running frequency of the main roller is greater than Start Freq[03], system starts, the AUTO LED
will be lit.
When S1 is ON, if the running frequency of the main roller is less than AUTO LED will
flash.
In automatic tension control systems, normally short-circuit the MC1 and MCC, the controller will start or stop the system
automatically according to the running frequency of the main roller.
Start Freq[03], system stops, the
4.2.3.1 Run/Stop switch
MC4
MCC
Start output
Selector
4.2.3 Run and stop operation
24V
DI0
GND
NPN Pulses
tension sensing roller pulses input
4.2.3.2 Start process
4.2.3.3 Stop process
4.2.3.4 Start output selection
When the system is running, once turn the switch S1 off, the output before stopping(turn MC1 off) times Stop Gain[11]
will be applied to the running reel to brake the reel, at the same time, the stop timer starts count, the controller perform
automatic control during stop process, when Stop Time[12] times up, the controller enters the opened loop control and
output the start output with value of P.on to generate prepared tension. In stopping mode, indicator AUTO flashes.
The start output of the controller is selected using the Start output selector S4.
When S4 is off, the output before stopping(turn MC1 off) will be used as start output.
When S4 is on, the presetting Start Output[ ]
Generally use start output selector as follow:
Start Output[
08 will be used as start output.
1. In normal operaions, keep S4 off, with the output memory function, the controller will restart
with the output before stopping.
2. When replacing new material reel, switch S4 on once, the controller will start with the pre-
setted 08].
MC1
MC1
MCC
MCC
S1 ON
S1 OFF
Run
Stop
S1
S1
S1: Run/Stop switch
S4
MC4
MCC
Run/Stop
command(MC1)
Run/Stop
command(MC1)
Automatic mode LED
AUTO
Automatic mode LED
AUTO
Flashes FlashesLit Lit
ON ONOFF OFFOFF OFF
Control output Control output
Stop Time[12]
Start Time[10] Start Time[10]
Stop Time[12]
Start Output[08]
start
output
start
output
P
Run/Stop Process: Start output selector is ‘OFF’ Run/Stop Process: Start output selector is ‘ON’
MC4
MCC
S4 is on
S4 is off
Flashes Flashes
PP

17
Tension Controller TC818
Suppose that Reel A is connected with Main Output A and Reel B is connected with Main Output B.
Aux. Time[15]. At the same time, the pre
If turning the Reel exchange switch from ON to OFF, this switches reel B to reel A, just
In unwind systems(Wind Mode[40]=Unwind), suppose that Reel A is running, at this time, turns the Reel exchange
switch from OFF to ON, the output on reel A will be kept and lasts for -setted
Exch. Out[13] will be applied to reel B, when the Exch. Time[14] times up, the automatic closed loop control starts.
reverse the above process. The
figure on the next page illustrates the process clearly.
4.2.4.1 Reel exchange switch
4.2.4.2 The exchange process
4.2.4 Reel exchange
Reel exchange
switch
Reel exchange
switch
Reel exchange
switch
MC2 MC2
MCC MCC
In the two-reel operation tension systems, the reel exchange is controlled by the Reel exchange switch.
This function is applicable when material on reel is over or full.
The reel exchange function is controlled by the switch which is connected to terminal MC2 and MCC. When the switch is
OFF, Reel-A will be active while the switch is ON, Reel-B will be active. See the figure above.
Switch OFF: Reel A is active Switch ON: Reel B is active
Output: PA, NA
Tension
sensor
Plating roller
Plating solution
Reel-B Magnetic
Powder Brake
Reel-A Magnetic
Powder Brake
TC818
Tension Controller
Output: PB, NB
MC2
MCC
8
TC81
s
Te ion Controller
n
U
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mm
%
k/
gN
UT
OTPU
/ON OFF
N LMA UA
AUTO
COM
LO K
C
AM
L
U
O TA OU B
T
AUTO
MAN
SetEsc

18
Tension Controller TC818
Reel Exchange Switch
MC2
MCC
Switch OFF: Reel A will be active;
Switch ON: Reel B will be active.
Reel Exchange
Time
Time
Aux. Time[15]
Reel A Reel A
Reel B Reel B
Reel B Output
Aux. Time[15]
Reel A Output
0
0
Exch. Time[14]
Exch. Output[13]
Exch. Time[14]
Exch. Output[13]