DFE WebHandler 3 User manual

INSTRUCTION MANUAL
WEBHANDLER 3
™
Tension ControllerDigital
DOC 801-1667
5 YEAR WARRANTY
DOVER FLEXO ELECTRONICS, INC.
ISO 9001 CERTIFIED

217 Pickering Road
Rochester, NH 03867-4630 U.S.A.
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©2006 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
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READ THIS!
Your WebHandler™Model 3 Digital 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 3 - Calibration and Set-Up
The other sections are for reference and for instruction if you wish to change the
configuration at some later time.

TABLE OF CONTENTS
SECTION ONE PRODUCT DESCRIPTION PAGE
1.1 General Description ........................................ 1
1.2 Outputs,VersionofController ................................ 2
1.3 WebHandler3™Controller Exploded View ....................... 3
1.4 Specifications............................................. 4
1.5 Standard Features ......................................... 5
1.6 Options ................................................. 6
1.7 Accessories .............................................. 6
SECTION TWO INSTALLATION
2.1 Dimensions .............................................. 7
ControllerEnclosure ....................................... 7
Pneumatics Enclosure ...................................... 7
2.2 Selection of Mounting Location ............................... 8
2.3 Power Voltage Selection .................................... 8
2.4 TransducerExcitation ...................................... 9
2.5 Customer Electrical Connections ............................. 9
Electrical Connections for Power Board, Standard and Options ..... 10
Electrical Connections for Standard Features .................... 11
Electrical Connections for Options and Accessories ............... 12
SECTION THREE CALIBRATION AND SET-UP
3.1 Initial Power-up and Overview of User Interface .................. 13
3.2 TensionCalibration ........................................ 14
3.3 Line Speed Calibration and Set-up ............................ 15
3.4 Roll Diameter Calibration and Set-up .......................... 20
SECTION FOUR SET-UP OF STANDARD & OPTIONAL FEATURES
4.1 BasicSet-upofController ................................... 23
4.2 Set-up of Optional Features .................................. 36
4.3 SpecialSet-upNotes ....................................... 37
4.4 TuningAdjustments........................................ 40
SECTION FIVE OPERATING INSTRUCTIONS
5.1 BasicOperation ........................................... 42
5.2 Operation of Additional Functions ............................. 43
SECTION SIX CARE AND MAINTENANCE ............................... 46
SECTION SEVEN TROUBLESHOOTING TIPS ........................... 47
SECTION EIGHT REPLACEMENT PARTS LIST
8.1 Standard Circuit Boards ..................................... 48
8.2 Optional Circuit Boards ..................................... 48
8.3 Output Modules ........................................... 48
8.4 Fuses ................................................... 48
8.5 Cables .................................................. 48
8.6 Relays .................................................. 48
APPENDICES
A CircuitBoards............................................. 49
B DIPSwitchSettings&Jumpers............................... 53
C Basic Set-up Sequence ..................................... 54
D Functions Menu Chart ...................................... 55
E DescriptionofFunctions .................................... 56
F Host Interface Commands and Responses ...................... 63
G PCWebLink Screens ....................................... 66
H Transducer Electrical Connections ............................ 69
I TypicalTensions .......................................... 73
Terms and Conditions ...................................... 74

LIST OF ILLUSTRATIONS
FIGURE: 1. Front Panel and Operator Devices ............................ 1
2. Examples of Tension Zones ................................. 2
3. Web Handler3 Controller - Exploded View ...................... 3
4. ControllerEnclosureDimensions ............................. 7
5. Pneumatics Enclosure Dimensions ........................... 7
6. PowerBoard ............................................. 8
7. Power Voltage Selection Switch .............................. 9
8. Transducer Excitation Voltage Switch .......................... 9
9. TerminalBoard............................................ 9
10. Electrical Connections for Power Board, Standard and Options ..... 10
11. Electrical Connections for Standard Features .................... 11
12. Electrical Connections for Options and Accessories ............... 12
13. DefaultDisplay............................................ 13
14. WebHandler3 Control Panel ................................. 13
15. WebPath ................................................ 15
16. DCTachometerOptionCard................................. 16
17. DC Tachometer Connections ................................ 16
18. DC Tachometer Card Switch Settings and Adjustments ........... 17
19. PulseTachometerCard..................................... 18
20. Pulse Tachometer Connections .............................. 18
21. Pulse Tachometer Card Switches and Adjustments ............... 19
22. JumperforE-Stop ......................................... 23
23. RS232 Cable Connections .................................. 24
24. RS232/RS485 Jumpers and Adjustments ....................... 25
25. RS485 Cable Connections .................................. 25
26. PCWebLink Run Screen .................................... 26
27. PCWebLink Config1 and Config2 Screens ...................... 27
28. PCWebLink TLS and Soft Start Screens ........................ 28
29. PCWebLink Calibration and Miscellaneous Features Screens ...... 28
30. PCWebLink Diagnostic Screens .............................. 29
31. PCWebLink Tuning and Data Transfer Screens .................. 29
32. Sort Start by External Contact Connections ..................... 32
33. Sample & Hold Connections ................................. 33
34. SecurityLockoutJumpers ................................... 33
35. Tension Limit Switch Output Connections ....................... 34
36. Connections for Remote Auto/Manual Set-pots and Switches ....... 36
37. Remote Tension Amp (RTA) Connections ...................... 36
38. V-OutBoard .............................................. 37
39. High Voltage Output Switch Settings ........................... 38
40. Isolated 10V Connections ................................... 38
41. Non-Standard Servo Valve Driver Card ........................ 39
42. Non-Standard Servo Valve Driver Output Jumpers ............... 39
43. Non-Standard Servo Valve Voltage Select Jumpers .............. 39
44. Connections for Non Standard Servo Valve ..................... 39
45. ControlBoard............................................. 49
46. PowerBoard ............................................. 49
47. TerminalBoard............................................ 50
48. V-OutBoard .............................................. 50
49. Driver Card for Non-Standard Servo Valve ..................... 51
50. IsolatedOutputCard ....................................... 51
51. DCTachometerCard....................................... 52
52. PulseTachometerCard..................................... 52
53. PCWebLink Run Screen .................................... 66
54. PCWebLink Screen Config1 and Config2 Screens ............... 66
55. PCWebLink TLS and Soft Start Screens ........................ 67
56. PCWebLink Calibration and Miscellaneous Features Screens ...... 67
57. PCWebLink Diagnostic Screens .............................. 68
58. PCWebLink Tuning and Data Transfer Screens .................. 68
59. C, RS, and UPB Transducer Wiring ........................... 69
60. RFTransducerWiring ...................................... 70
61. TR,NWTransducerWiring .................................. 71
62. LTTransducerWiring ...................................... 72

1
SECTION 1 PRODUCT DESCRIPTION
1.1 GENERAL DESCRIPTION
The WebHandler™Model 3 digital tension controller automatically maintains tension of any continuous
material at the value selected by the machine operator. Basic functions are divided into three parts:
The first part is the tension amplifier, which supports all Dover Flexo Electronics tension transducers. (The
transducers measure the actual tension in the web). It includes a regulated power supply to excite the
transducers, an amplifier to boost the transducer output signal, and a calibration circuit to adjust the tension
readout to display actual tension.
The second part is the tension regulator. It compares the output signal from the transducers with the Auto set-
point value. If there is a difference, the regulator will either increase or decrease its output signal to equalize
them. The tension amplifier is located on the front board. The tension regulator function is performed in
software which is executed by the processor on the Control Board. See Figure 3 for board locations, and
Appendix A for board views.
The third part is the output circuit. It accepts the output from the tension regulator and actuates a brake, clutch,
or variable speed DC or AC drive which actually creates the tension in the web.
There is a location on the Control Board for a plug-in card containing an isolation module for the isolated output
option.
Figure 1 - FRONT PANEL and OPERATOR DEVICES

2
TENSION ZONES
Tension zones are created by driven or braked nip rolls, drag bars, braked or 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 WebHandler3™ 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
1.2 OUTPUTS, VERSIONS OF CONTROLLER
The WebHandler™Model 3 controller is available with one of four outputs:
A. Pneumatic output. (Version P). This is used to actuate any air operated brake or clutch. The standard
version includes a servo valve, air filter and pressure regulator installed in an separate enclosure. The output
range is 0.5 to 75 psi.(0.03 bar to 5.17 bar). Also see D. below.
B. High Voltage output. (Version V). This output uses Silicon Controlled Rectifiers (SCR’s) to produce a
standard variable voltage of up to 90Vdc to operate any electric brake or clutch, including eddy current
clutches. 45 volt, and 24 volt outputs (24V not available with 230Vac input) are optional.
C. 0-10Volt DC compensated output module. (Version D). This output is used to control DC drives or other
variable speed drive systems. This output can be isolated from earth ground to make it more compatible with
all drives. See Options, Section 1.6, for more details.
D. Driver Card. (Version C). This version provides power and signal outputs for non-standard pneumatic
servo valves.

3
1.3 WebHandler3™EXPLODED VIEW
Figure 3 - WebHandler™Model 3 EXPLODED VIEW

4
1.4 SPECIFICATIONS (separated into Versions V, D, C or P where applicable)
Power Input:
VersionsP,D,C:........................ 115/230 Volts 60/50Hz single phase @ 1 Amp
VersionV: ........................ 115/230 Volts 60/50Hz single phase @ 6 Amps
Output:
VersionP: ........................ 0.5 to 75 psi (0.03 to 5.17 bar)
VersionV: ........................ 0to90, 45, or 24 Vdc, all @ 5 Amp with 115 Vac In
OR
0 to 90 Vdc, 45 Vdc all @ 5 Amp with 230 Vac In
Version D: 0 to ±10 Vdc, Compensated (Optional Isolated signal
available)
VersionC: ........................ +15Vdc@250madc or 24VAC @ 200mA to power a
servo valve
Enclosure: ........................ Steel,powderresinpainted,NEMA1
Weight: ........................ 9lbs.(4.1 kg)
Transducer Signal Accepted .............. 500 mVdc per pair at rated load (1000 mV with XR
option)
Mating Transducer Cable Connectors ...... AmphenolMS3106A-10SL-3S
Zero (Tare) Range: ...................... 95%oftransducerrating,minimum
Calibration Range: ...................... 25:1max.
Temperature Range: ..................... 32°Fto104° F (0° C to 40° C)
System Accuracy: ....................... Within1to3%typical
Output Range, Automatic mode: ........... 0to100% of rated output (See output)
Manual Mode Output Range: .............. 0to100% of rated output
Standard Tension Meter Ranges: .......... 0-1,5,10, 25, 50, 75, 100, 150, 200, 250, 300, 500,
1000, 1500, 2000, 2500, 3000
Taper Tension Range (option): ............. 0to100%
Taper Tension by Rider Roll / Diameter Sensor. . 0 to 10 Vdc input
Pneumatic Enclosure (Version P, only) ...... Input: 125 psi Max.,
Output: 0.5 to 75 psi (0.03 to 5.17 bar)
Servo Valve Drive Signal: 4 to 20mA
Air Connection In. 3/8" NPT
Air Connection Out. 1/4" NPT
Weight: 2.84 lbs. (1.28 kg.)