DFE STEADYWEB 6 Product manual

TECHNICAL REFERENCE MANUAL
Digital Tension Controller
STEADYWEB™6
DOC 801-2540

307 Pickering Road
Rochester, NH 03867-4630 U.S.A.
For assistance, please call:
TECHNICAL SERVICE - Installations, Start-Up, Troubleshooting, Repairs, Field
Service, Returns. [email protected]
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SALES - Product Information, Systems Application Questions, and
placing orders for standard products and special systems.
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©2019 Dover Flexo Electronics, Inc. All rights reserved. Dover Flexo Electronics has made reasonable effort to ensure accuracy of this
document. However NO WARRANTY, whether expressed or implied, is given regarding the completeness or correctness of information in
this document. Dover Flexo Electronics shall not be liable for damages of any kind arising from the use or misuse of this document. Dover
Flexo Electronics reserves the right to make changes, additions, and deletions to this document without notice and without obligation.

READ THIS!
*** SAFETY INFORMATION ***
Please read this manual prior to installing and operating the controller. Take care to follow
local codes and only allow properly trained individuals to operate or service the equipment.
Failure to follow the manual's instructions and practice safe working habits could result in
property damage, personal injury and/or death.
n WARNING:
Before servicing the SteadyWeb 6, power should be removed from the device. Failure to do
so could result in property damage, personal injury and/or death.
n CAUTION:
The SteadyWeb 6 contains circuit boards with static sensitive devices. When working
directly with these circuit boards, users should always practice proper grounding techniques,
including the use of ground straps.
*** INSTALLATION AND SETUP INFORMATION ***
Your SteadyWeb 6™ Controller has been properly configured at our factory. To install it and
start it up, it should only be necessary to use these sections of this manual:
Section 2 - Installation
Section 4 - Calibration
Section 6 - Tuning Adjustments
The other sections are for reference and for instruction if you wish to change the
configuration at some later time.
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TABLE OF CONTENTS
SECTION ONE PRODUCT DESCRIPTION PAGE
1.1 General Description ............................................ 1
1.2 Tension Zones ................................................ 2
1.3 Versions of the Controller ....................................... 3
1.4 Specifications................................................. 3
1.5 Environmental Conditions ....................................... 5
1.6 Standard Features ............................................. 5
1.7 Options ..................................................... 7
1.8 Accessories..................................................7
SECTION TWO INSTALLATION
2.1 Dimensions .................................................. 8
2.2 Selection of Mounting Location ................................... 9
2.3 Safety & EMC Requirements..................................... 10
2.4 Installation Instructions ......................................... 12
2.5 Transducer Voltage Selection .................................... 12
2.6 Control Output Selection........................................ 13
2.7 Tension Output Selection ....................................... 14
2.8 Emergency Stop Configuration................................... 14
2.9 Customer +10/15V Output Selection............................... 15
2.10 Power Electrical Connections .................................... 16
2.11 Standard Electrical Connections .................................. 17
2.12 Option Card Mounting Locations .................................. 20
2.13 Pulse Tachometer Option Card Electrical Connections................. 20
2.14 DC Tachometer Option Card Electrical Connections .................. 21
2.15 Relay Option Card Electrical Connections........................... 21
2.16 External Output Module Cable Connections ....................... 22
2.17 High Voltage Output Module Electrical Connections ................... 23
2.18 Communication Options Cards Electrical Connections ................. 23
SECTION THREE USER INTERFACE OVERVIEW
3.1 Main Interface Description....................................... 24
3.2 Display Modes Descriptions ..................................... 24
3.3 Menu Display Mode and Navigation ............................... 25
3.4 PID Tune View................................................ 26
SECTION FOUR CALIBRATION
4.1 Tension Calibration............................................ 27
4.2 Line/Roll Speed Input Calibration ................................. 29
4.3 DC Tachometer Calibration...................................... 30
4.4 Pulse Tachometer Calibration.................................... 31
4.5 Diameter Input Calibration....................................... 33
4.6 Signal Filtering ................................................ 34
SECTION FIVE SETUP
5.1 Control Feedback Modes........................................ 35
5.2 Unwind Zone Setup ............................................ 35
5.3 Intermediate Zone Setup ........................................ 36
5.4 Rewind Zone Setup ............................................ 37
5.5 Soft Start Setup............................................... 38
5.6 Sample and Hold/Ratio Setup .................................... 39
5.7 Tension Limit Switch Setup...................................... 40
5.8 Diameter Alarm Setup.......................................... 40
5.9 Inputs Setup.................................................. 41
5.10 Relay Option Setup............................................ 42
5.11 Communication Options Setup ................................... 42
5.12 Tension On Relay Option ....................................... 43
5.13 Power On Settings............................................. 43
5.14 Anti-Tamper/Security Lockout ................................ 43
SECTION SIX TUNING ADJUSTMENTS
6.1 PID Control Tuning ............................................ 44
6.2 Tuning Procedure ............................................. 44
6.3 Tuning Examples.............................................. 45
6.4 Advanced Tuning Adjustments ................................... 46
6.5 Diameter Compensation ........................................ 46
6.6 Acceleration Compensation...................................... 47
SECTION SEVEN OPERATING INSTRUCTIONS
7.1 Basic Operation............................................... 48
7.2 Display Adjustments ........................................... 48
7.3 Saving and Recalling Setups..................................... 48
7.4 Transferring Setups to PC via USB................................ 48
7.5 Setting Auto/Manual Setpoints ................................... 48
7.6 Using Taper .................................................. 48
7.7 Resetting TLS Alarms.......................................... 48
7.8 Resetting Diameter Alarm....................................... 48
7.9 Zeroing Tension............................................... 48
SECTION EIGHT CARE AND MAINTENANCE ................................... 49

SECTION NINE TROUBLESHOOTING
9.1 General Troubleshooting Tips .................................... 50
9.2 Error Messages ............................................... 50
9.3 Diagnostic Screens ............................................ 52
SECTION TEN REPLACEMENT PARTS ...................................... 55
APPENDICES
APPENDIX: A Location of Jumpers and Adjustments (Figure 49) .................... 56
B Menu Hierarchy (Figure 50)...................................... 57
C Electrical Connections (Figures 51-52) ............................. 58
D Transducer Electrical Connections (Figure 53-54) ................... 60
E Typical Tensions of Various Materials.............................. 62
F Environmental Terms .......................................... 63
Terms and Conditions of Sale and Shipment ........................ 64
Index ....................................................... 65
LIST OF ILLUSTRATIONS
FIGURE 1. Front View of SteadyWeb6 ...................................... 1
2. Examples of Tension Zones ..................................... 2
3. Enclosure Version Dimensions and Views .......................... 8
4. Panel Version Dimensions and Views .............................. 8
5. Pneumatic Enclosure Dimensions for Version P ...................... 9
6. High Voltage Output Enclosure Dimensions for Version V .............. 9
7. Enclosure Version Service Access ................................ 11
8. Output Jumpers............................................... 14
9. Setup Jumpers................................................ 15
10. 24VDC Power Electrical Connections .............................. 16
11. AC Power Electrical Connections ................................. 17
12. Standard and 0-10VDC Control Board Electrical Connections . . . ........ 18
13. Control Board Transducer Electrical Connections and Remote Option..... 19
14. Option Card Mounting Locations .................................. 20
15. Pulse Tachometer Electrical Connections ........................... 20
16. DC Tachometer Electrical Connections............................. 21
17. Relay Electrical Connections ..................................... 21
18. 24VDC Connections for Brakes and Clutches........................ 22
19. External Output Module Cable Connections ......................... 23
20. High Voltage Output Module Electrical Connections ................... 23
21. SteadyWeb6 User Interface...................................... 24
22. Main Menu Screen............................................. 25
23. PID Tune View Screen ...................................... 27
24. Selection of Tension Units.................................... 27
25. Selection of Tension Range .................................. 27
26. Selection of Tension Source.................................. 27
27. Selection of Calibration Weight................................ 27
28. Selection of Transducer Type................................. 28
29. Review of Calibration Settings................................. 28
30. Zero Transducer Screen..................................... 28
31. Zero Operation Complete ....................................... 28
32. Web Path For Calibration ....................................... 28
33. Cal Not Ready ............................................... 29
34. Cal Ready ................................................... 29
35. Cal Successful................................................ 29
36. DC Tachometer............................................... 30
37. Pulse Tachometer............................................. 32
38. Anti Tamper Lockup Jumper..................................... 43
39. Tuning Screen Showing Overshoot ................................ 45
40. Tuning Screens Showing Adjustment Responses..................... 45
41. Derivative Noise............................................... 45
42. Screens Showing Wobble ....................................... 46
43. Diameter Compensation PID Transition ............................ 47
44. Control Board Showing Jumper Locations .......................... 56
45. Menu Hierarchy ............................................... 57
46. Standard and 0-10Vdc Control Board Electrical Connections . . . ......... 58
47. Control Board Transducer Electrical Connections and Remote Option..... 59
48. Models C, RS, F, TR, and NW Transducer Wiring .................... 60
49. RFA, LT, and VNW Transducer Wiring ............................. 61

1 PRODUCT DESCRIPTION
1.1 GENERAL DESCRIPTION
The SteadyWeb™6 is a digital tension controller designed to automatically maintain tension of any continuous
material at a value selected by the equipment operator. The controller combines ease of use with powerful
control features and capability that allow for effortless configuration and utilization over a wide variety of tension
control applications.
The SteadyWeb™6 can be powered by 24VDC or with a built-in 100-240VAC power supply and is available in
panel mount and enclosure mount configurations. The controller is offered in multiple output versions. The user
interface features a context-sensitive 5" touch screen display. Illustrated prompts and color graphics make set up
easy and allow for a short operator learning curve.
Basic functions of the controller are divided into three components: amplifier, tension regulator and output
converter.
Figure 1 - FRONT VIEW OF SteadyWeb™6
1. Amplifier
The first component is a tension amplifier, which supports all Dover Flexo Electronics tension transducers (the
transducers measure the actual web tension). It includes a regulated power supply to excite the transducers
and circuitry to amplify and measure the transducer output signal. Intelligent excitation circuitry provides
automatic excitation voltage selection and monitors for transducer wiring errors or fault conditions, such as a
short circuit or open circuit conditions.
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1.1 GENERAL DESCRIPTION continued....
2. Tension Regulator
The second component is the tension regulator. The controller compares the measured tension to the Auto
setpoint value and adjusts an output signal to equalize the measured and desired tension. The regulator
function is performed by software and may be influenced by other signal inputs, such as web speed and roll
diameter, as dictated by operator-adjustable settings. Regulation is achieved with a PID (Proportional,
Integral, Derivative) based control loop with advanced capabilities such as roll diameter compensation and
web acceleration compensation.
3. Output Converter
The third component is the output stage, the signal from which is used to actuate a brake, clutch, or variable
speed DC or AC drive which in turn creates the actual web tension. The output stage is available in several
application-dependent versions. Standard in every controller is an isolated control output (adjustable range
within the limits of ± 10 Volts or 4-20 mA). Optionally, a 0-24VDC output stage may be included internal to the
controller to drive 24V devices drawing up to 2.5A. Higher current 0-24V devices may draw customer-
supplied power through the controller's terminals. Optional external output modules are available to drive
higher voltage electrical devices with 0 – 45/90 VDC @ 5 Amps and pneumatic devices with 2 – 75 psi.
n WARNING:
The isolated output is designed to prevent ground loops and noise. It is not intended or approved for safety
isolation of hazardous voltages. Do not install unit where the isolated circuit and chassis ground are more than
40Vpk differential.
n WARNING:
AC versions of the SteadyWeb™6 controller are designed for single phase AC operation only. To prevent product
damage and potential hazard, do not connect them across three phase lines or three phase circuits.
1.2 TENSION ZONES
Tension zones are created by driven or braked nip rolls, drag bars, braked unwind, driven unwind, or rewind
shafts, or anything else that can increase or decrease web tension. One of these elements is at each end of
every tension zone.
Many machines that process a continuous web have more than one tension zone. The SteadyWeb™6 controller
can be used in all tension zones, when properly configured for the zone it will be used in. See Figure 2 for
examples of tension zones.
Figure 2 - EXAMPLES OF TENSION ZONES
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1.3 VERSIONS OF THE CONTROLLER
The SteadyWeb™6 controller is available in multiple output, mounting and power configurations as described
below.
A. OUTPUT The SteadyWeb™6 is available with one of three outputs:
1. Standard Isolated Output (D). The standard D version is used to control DC drives or other variable
speed drive systems. It offers a jumper-selectable voltage or current output. The voltage output is from 0
to +/-10VDC, or a user-adjustable range within that window, such as 0 to 10VDC, 0 to +/-5VDC, etc. The
current output uses an industry standard 4 to 20mA signal. The control output is isolated from chassis and
transducer ground.
n WARNING:
The isolated output is designed to prevent ground loops and noise. It is not intended or approved for
safety isolation of hazardous voltages. Do not install unit where the isolated circuit and chassis ground are
more than 40Vpk differential.
2. Pneumatic Output (P). The P version is used to actuate any air operated brake or clutch. It includes a
servo valve, air filter and pressure regulator installed in a separate enclosure which is fed a 4-20mA signal
from the D version of the controller (as described above). The pneumatic output range is 1 to 75 psi (0.07
bar to 5.17 bar).
3. High Voltage Output (V). Embedded within the SW6 Controller is a standard 24V output stage to drive
24V brakes and clutches up to 2.5A drawn current. Devices drawing more than 2.5A at 24V can be
accommodated with guidance from DFE Engineering. To operate brakes or clutches at more than 24V,
including eddy current clutches, the 45 and 90 Vout options are available in an outboard module which is
fed a 0-10V signal from the D version of the controller (described above) and employs a Silicon Controlled
Rectifier (SCR) to deliver variable voltage of up to 90VDC. The 24VDC output is not available with the
230VAC input.
B. MOUNTING The controller is available in two mounting configurations.
1. Open Mount (O). The open (panel) mount version can be mounted directly into a cabinet or enclosure
cutout.
2. Enclosure Mount (E). The enclosed version can be mounted against any surface strong enough to
reliably support the controller.
C. POWER The controller is available in two power versions.
1. 24VDC (24). The DC version is powered from a 24VDC +/-10% supply.
2. AC (AC). The AC version includes a universal AC power supply, which can be powered from a 100-
240VAC, 50-60Hz supply.
n WARNING:
AC versions of the SteadyWeb™6 controller are designed for single phase AC operation only. To prevent
product damage and potential hazard, do not connect them across three phase lines or three phase
circuits.
1.4 SPECIFICATIONS
Power Input:
DC:
• 24VDC +/-10% , 0.6 Amps Typical, 2.2 Amps Internal
Fusing (resetting thermal fuse)
Optional AC Supply:
• 100-240VAC +/-10%, 50-60Hz single phase
• 2.2 Amps @ 115VAC Typical
• 1.2 Amps @ 230VAC Typical
• Inrush Current 40A @ 230VAC (cold start)
Control Output:
Version D
• 0 to +/-10VDC OR 4-20mA (jumper-selectable), both
isolated from input power and transducer circuitry
• 0 to +/-10VDC max loading is 5mA. This requires a
2000 Ohm or greater input resistance for equipment
connected to this output
• 4-20mA max loop resistance is 500 Ohms.
Transducer Signal Input:
• 500mV at rated load per pair of STD transducers
• 1,000mV at rated load per pair of XR transducers
Customer 10/15VDC Supply:
• 10/15VDC (jumper-selectable), 100mA max load.
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1.4 SPECIFICATIONS continued . . .
Transducer Excitation:
• 5VDC for STD transducers, 10VDC for XR
transducers (automatically software set per sensed
transducer resistance, or manually fixed through user
configuration settings)
• 35mA per half bridge (70mA total) software short
circuit protection
• Duration of excitation short-circuit: Infinite
Tension Output:
All Versions:
• 0 to +10VDC OR 0 to 1mA (jumper-selectable)
• 0 to +10VDC max loading is 5mA. This requires a
2000 Ohm or greater input resistance for equipment
connected to this output
• 0 to +10VDC and 0 to 1mA signal capable of under-
range and over-range, -14% to 120% of full scale (-
1.4VDC to 12VDC / -0.14mA to 1.2mA), to indicate
over-range or error conditions
• 0 to 1mA meter output designed for 50 Ohm
impedance meter.
Digital Inputs:
• Soft Start, Hold, Ratio, Remote Tension On, Remote
Tension Off, Remote Auto, Remote Manual
• Activated by contact with power ground (falling edge)
• Internal weak pull-up resistors to 3.3VDC
• Max 24VDC input protection
Digital Outputs:
• 3.3V digital diameter alarm output
Analog Signal Inputs:
• Line Speed, Roll Speed, Diameter, Remote Auto
Setpoint, Remote Manual Setpoint, RTA1, RTA2
• Designed for 0-10VDC input signal, 0-12VDC range
sense capability
• Max 24VDC input protection
Tension Precision:
• Max error of 1% over temperature range. 0.1%
Typical
Zero (Tare) Range:
•Minimum 95% of transducer rating
Calibration Range:
• 50:1 max
Control Loop Time:
• Less than 5mSec
Transducer Tension Analog to Digital Converter
(ADC) Resolution:
• 16-Bit at 242Hz sample rate
• 20.62μV Resolution with 5V Excitation (STD
Transducers)
• 41.24μV Resolution with 10V Excitation (XR
Transducers)
Analog Signals* Analog to Digital Converter (ADC)
Resolution:
• * (Line Speed, Roll Speed, Diameter, Remote Auto
Setpoint, Remote Manual Setpoint, RTA1, RTA2)
• 12-Bit at 242Hz sample rate
• 2.93mV Resolution
Control Output Digital to Analog Converter (DAC)
Resolution (D Version):
• 12-Bit at 242Hz update rate.
• -10VDC to 10VDC Out: 6.0mV Resolution
• 4-20mA Out: 9.6μA Resolution
Tension Output Digital to Analog Converter (DAC)
Resolution:
• 12-Bit at 242Hz update rate.
• 0-10VDC Out: 3.3mV Resolution
• 0-1mA Out: 0.33uA Resolution
Pneumatic Enclosure (Version P only):
• Air Input: 125 psi Max.
• Air Output: 2 to 75 psi (0.07 to 5.17 bar)
• Servo Valve Drive: Signal: 4 to 20mA
• Air Connection In: 3/8" NPT
• Air Connection Out: 1/4" NPT
Weight:
• DC Panel Mount: 1.6 lbs. (0.73 kg)
• AC Panel Mount: 3.1 lbs. (1.41 kg)
• DC Enclosure Mount: 5.1 lbs. (2.32 kg)
• AC Enclosure Mount: 6.6 lbs. (3.00 kg)
• Pneumatic Module: 4.6 lbs. (2.09 kg)
• High Voltage Output Module: 2.9 lbs. (1.32 kg)
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