Montalvo X-3000-ce-RW User manual

Instruction Manual
Rewind Tension Controller
X-3000-ce-RW
MANUAL
MANUAL/
AUTO
AUTO
TENS ION
OF F / ON
LOW /
HIGH
TAP ER
20 80
50
20 80
50
20 80
50
OUT PUT
R1 R2 R3 R4 R5 R6
DO 1-4
DI 1-8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
L N PE
TENSION 45 %
Type : X/D-3000
Seri al no : 960034
Voltage : 115V/230V AC
Current : 160mA/80mA
L N PE
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
97.05.05 GB REV 2.0

1
1 GENERAL DESCRIPTION 2
2 TECHNICAL DATA 3
2.1 X-3000-CE ELECTRICAL 3
2.2 X-3000-CE MECHANICAL 3
3 INSTALLATION 4
3.1 CONTROLLER MOUNTING 4
3.2 ELECTRICAL INSTALLATION 4
3.3 TERMINAL BLOCKS 5
3.4 TERMINAL BLOCK DESCRIPTIONS 6
3.5 WIRING DIAGRAM 10
3.6 OPERATING THE CONTROLLER MENU 12
3.7 MENU TREE SURVEY 14
3.8 LOAD CELL REWIND - X RW 15
3.9 SETUP FUNCTIONS 16
3.10 MECHANICAL INSTALLATION 17
4 CALIBRATION 20
4.1 DESCRIPTION OF ADJUSTMENTS 20
4.2 TENSION CALIBRATION 21
4.3 TAPER CALIBRATION 22
4.4 TUNING 23
4.5 FRONT PANEL CIRCUIT BOARD SETTINGS 23
4.6 CUSTOMER PARAMETER SETTINGS 23
5 OPERATION X-3000-CE 24
6 TROUBLESHOOTING 25

2
1 General Description
The Montalvo X-3000-ce PID analog controller
provides precise automatic control of web tension. The
progressive PID regulator automatically compensates
for roll diameter. The X-3000-ce is used in a closed
loop, of which the load cell roll and motor or clutch
are a part.
In order to properly set up and operate the X-3000-ce, as
well as be able to take advantage of all of the available
features, it is important to have a general understanding of
the controller and how it fits into the tensioning system
(please refer to the diagram below). The control outputs
of 4 to 20 mA and 0 to 10 volts DC enable the X-3000-ce
to interface with a variety of output devices to control web
tensioning brakes, clutches and motors.
Load Cell Function
Two load cells (also called transducers) are normally used.
The signals from the load cells are summed together to
give the total web tension across the entire web. Each load
cell contains 2 strain gauges connected in series. The two
load cells are connected so that the 4 strain gauges form a
Wheatstone bridge configuration supplied with ±2.5V
DC. The web tension transfers a force to the load cell roll,
causing the resistance values in the bridge to change. The
resulting voltage change is amplified and calibrated at the
regulator card.
Motor/ Clutch Function
One or more motors may be controlled, converting the
electrical signal into torque. This torque in turn changes
the web tension.
Auto Mode Function (closed loop)
The operator sets the desired tension, using the auto
setpoint potentiometer. The feedback from the load cells
is calibrated to display the actual web tension. This signal
is compared with the desired tension (setpoint) and the
regulator automatically adjusts the output to make the
actual tension the same as the desired tension. Because the
web itself is part of the feedback loop, the X-3000-ce can
quickly compensate for speed and diameter changes, as
well as other factors that may affect tension during the
process.
Manual Mode Function (open loop)
The operator sets the desired output torque, using the
manual potentiometer. The web tension is still measured
and displayed on the tension meter, but no automatic
regulation is done in this mode. The operator must make
constant adjustments to maintain tension.



Motor controller
Motor
MANUAL
MANUAL/
A UTO
AUTO
TENSION
OFF / ON
LOW/
HIGH
TAPER
20 80
50
20 80
50
20 80
50
OUTPUT
Load cell

3
2 Technical Data
2.1 X-3000-ce Electrical
AC Input
115 or 230 VAC ±10 % (IEC TC77B WG3)
48 to 62 Hz
Fuse Size
115 V - 160 mA T (slow-blowing type) Ø 5 - 20 mm
230 V - 80 mA T (slow-blowing type) Ø 5 - 20 mm
Overvoltage Category
II (IEC 664)
2 kV in 1 min. Primary to secondary
Pollution Degree
3
Material Fire Classification
94V0
Max. Power Consumption
12 VA
Max. Fuse ahead
10A
Noise Immunity
EN 50082-2 industrial
Noise Emission
EN 50081-1
Load Cell Supply
±2.5 VDC ±5%
Load Cell Input
0 to ±250 mVDC
Zero Range (tare)
50 % of load cell rating
Calibration Range
Gain - 11 to 480
Temperature Range
0 to 50 °C (32 to 122°F) operating
-10 to 80°C (14 to 176°F) storage
Degree of Protection
IP 54
Regulator Outputs
0 to 10 VDC
Maximum load - 5 mA
4 - 20 mA / 0-20 mA
RL= 0 to 1000 Ω
Meter Outputs
0 to 100 µA
RO= 100 KΩ
0 to 10 VDC
Maximum load - 5 mA
Analog Input Voltage
0 to 10 VDC
RI= 1000K
Digital Input Voltage
15 to 30 VDC
RI= 10K
Digital Output Voltage
24V DC ±15%
Maximum load - 100mA
Total load 4 outputs 350mA
Standards
Designed to meet UL 508 and EN 60204
2.2 X-3000-ce Mechanical
Dimensions L x W x H
330 x 260 x 163 mm
Weight
4 kgs
MANUAL
MANUAL/
AUTO
AUTO
TENS I ON
OFF / ON
LOW /
HIGH
TAP ER
20 80
50
20 80
50
20 80
50
OUTPUT
Dimensions L x W x H Panel version
160 x 160 x 60 mm
Weight Panel version
1.0 kg
R1 R2 R3 R4 R5 R6
DO 1-4
DI 1-8
1 2 3 4 5 6 7 8 9 10 11 12 13 1415 16 17 18 19 20 2 1 22 23 24 25 26 27 28 2 9
L N PE
TENSION 45 %
Type : X/D-3000
Serial no : 960034
Voltage : 115V /230V AC
Current : 160mA/80mA
L N PE
30 31 32 33 34 35 36 37 38 3940 41 42 43 44 45 46 47 48 49 5 0 51 52 53 54 55 56 57 58

4
3 Installation
3.1 Controller Mounting
The X-3000-ce should be mounted in a dry place, away from
any source of heat. The mounting surface should be free of
any excessive vibration. If possible, the controller should be
mounted at eye level and in a location that is accessible to the
operator. If an I/P converter is used, it should be mounted as
close to the brake as possible.
Avoid mounting the circuit board close to drive
controllers or any other equipment that produces large
amounts of EMI.
3.2 Electrical Installation
Warning: The electrical installation must be done
by skilled personnel. Wiring must meet all
applicable codes and standards.
Refer to the appropriate wiring and terminal descriptions for
external connections.
Be sure the voltage selector on the regulator PCB is in the
correct position for the voltage supplied.
The PCB fuse size must be selected according to the input
voltage selected. The maximum external fuse on the input is
10 A.
If using load cell cables that mate to Amphenol connectors on
the bottom of the cabinet, the “G” (shield) end of the cable
connects to the X-3000-ce.
Please note: 0V DC and PE is internally connected.
Please note: Double check the accuracy of all wiring
connections before applying power to the controller.
Damage caused by improper wiring is not covered under
warranty.
EMC Requirements
The protective ground wire must be connected to the terminal
marked PE. Ground wires should be as short as possible.
For printed circuit board versions, PE, the mounting plate and
the cabinet must be connected to a common ground.
Shielded cable must be used for all external connections and
the shield terminated at the controller end only for analog
signals and at both ends for digital signals. For enclosure
versions, the shield may be connected to the cabinet at the
point where the cable enters, either to a bus bar or to the
connector housing. Keep the shield as short as possible (not
to exceed 10 mm or 0.4 inches). The best way to connect a
shield is to unisolate a piece and put a holder 360°around the
cable.
Keep signal cables away from supply cables or any wires
that conduct high current. For best noise immunity, run
signal cables close to the machine frame, mounting plates or
other grounded structures.

5
3.3 Terminal Blocks
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
DI2 / Splice
DI4 / High calibration
+24V
DI6 Web Pulse
DI8 Inertia
+24V input for DO
DO2
DO4
0VDC
Manual / DI1
Tension OFF / DI3
+24V
+24V
Start / DI5
Brake Pulse DI7
WB / DO1
DO3
-2.5V
-2.5V +2.5V
+2.5V
+Load cell input, dancer input
-Load cell input
+10V
+10V
+10V
+10V
-10V
Regulator output 4-20mA
Regulator output 0-10V
Tension output 0-10V
Tension output 0-100uA
Auto setpoint 0-10V
Taper setpoint 0-10V
Diameter output calibrated 0-10V
Diameter/trim input +10V
Extra output 4-20mA/0-20mA
Input for extra output 4-20mA/0-20mV
Extra analog output 0-10V
External gain 0-10V
Summation input 0-20V
Splice setpoint 0-10V
Manual setpoint 0-10V
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC

6
3.4 Terminal Block Descriptions
Basic Connections - Required for All Applications
115 / 230 VAC Supply
The controller must be supplied with the voltage indicated on
the voltage selector switch on the printed circuit board.
X10.1 Supply Voltage - L
X10.2 Supply Voltage - N
X10.3 PE - Ground
For protective conductor.
Regulated Outputs
X1.15 0V DC
Regulated voltage or current signal common. Connects to
input ground of the converter.
X1.17 Regulated Voltage
0 to 10 V output corresponding to 0 to maximum output from
the regulator. Used for recorder or output meter. May also
be used to control variable speed drives operating in the
torque mode. Maximum load = 5 mA.
X1.16 Regulated Current
Regulated current signal to the I/P or other converter for
clutch.
4-20 mA signal 1 +
2 -
Supplies
X1.4,33,36 +24 V Supply
Unregulated 22 to 28 volt DC supply for external
use. Maximum load - 100 ma.
X1.1,8,11,15,18,21,24,28,30,37,40,44,,47,50,53,56
0V DC
Common for signal and contact inputs and outputs.
Load Cell Connections
The following connections are necessary only when wiring
the load cells directly into the printed circuit board. If
Amphenol connectors are used, these connections have been
made at the factory.
X1.12 - 2.5 V Supply
Connects to pin ‘b’ on load cell 1. Black wire.
X1.13 + Load Cell Input
Positive-going load cell input. Connects to pin ‘a’ on load
cell 1. White wire.
X1.14 +2.5 V Supply
Connects to pin ‘c’ on load cell 1. Red wire.
X1.41 + 2.5 V Supply
Connects to pin ‘b’ on load cell 2. Black wire.
X1.42 - Load Cell Input
Negative-going load cell input. Connects to pin ‘a’ on load
cell 2. White wire.
X1.43 -2.5 V Supply
Connects to pin ‘c’ on load cell 2.
Red wire.
R1 R2 R3 R4 R5 R6
DO 1-4
DI 1-8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
L N PE
TENSION 45 %
Type : X/ D-3000
Serial no : 960 034
Voltage : 115V/230V AC
Current : 160mA/80mA
L N PE
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
11 12 13 14 15 16 17
40 41 42 43 44 45 46
RED
WHITE
BLACK
LOAD CELL 1
CABLE
0VDC
+2.5V
-2.5V
-INPUT
RED
WHITE
BLACK
LOAD CELL 2
CABLE
0VDC
-2.5V
+2.5V
+INPUT
REGULATED CURRENT
REGULATED VOLTAGE
0VDC
Colors ref. to standard cables supplied from Montalvo.

7
Optional Connections - Used for Rewind Applications
X1.50 0V DC
Connects to the CCW terminals (1) of the splice level poten-
tiometer.
X1.51 Splice Level
Input for external signal is used to set output during splice
mode. A 0 to 10 volt input corresponds to 0 to maximum
output.
X1.52 10 V Reference
Reference voltage applied to the CW terminals (3) of the
splice level potentiometer. Total max. load 5mA.
X1.24 0V DC
Connects to the CCW terminals (1) of the diameter potentio-
meter.
X1.25 Diameter Input
Diameter reference input. Maximum 0 to 10 V with
reference to 0V DC. Signal may be supplied from a
potentiometer, ultrasonic sensor or diameter calculator.
X1.27 10 V Reference
Reference voltage applied to the CW terminals (3) of the
diameter potentiometer. Total max. load 5 mA.
X1.6 Inertia
When activated by a 24 V input or a contact to X1.36, the
output increases by a level set in the INERTIA menu. This
function is used to compensate for the mechanical inertia of
the rewind at start up. It is activated when the main drive is
started.
X1.31 Manual
When activated by a 24 V input or a contact closure to
X1.33, the controller switches to the manual mode. Output is
set by the potentiometer marked MANUAL. When de-
activated, the controller regulates from the manual value.
X1.2 Splice
When activated by a 24 V input or a contact closure to X1.4,
the output switches immediately to the new roll, starting
output determined by the setting of the external splice level
potentiometer. This function is used for flying splice
automatic roll changes and is normally activated by the knife
firing circuit. Rewind splice level is typically set for 5 - 20 %
of maximum to provide the correct torque for the new core
diameter, but the actual setting depends on the application.
The splice level is held constant for a time determined by the
setting of the splice time in the SPLICE menu.
X1.34 Start
When activated by a 24 V input or a contact closure to
X1.34, the regulator is released and begins to integrate up to
the tension set point. Start should be activated when the
rewind motor is started.
X1.3 High Calibration
When activated by a 24 V input or a contact closure to X1.4,
the second calibration range is used. Calibration for this
range is adjusted by potentiometers R3. This feature is used
if the controller is used over a wide tension range or if there
are two different web paths.
X1.35 Roll Pulse
Puls from the rewind roll to calculate the diameter. There can
be more pulses per rev. The number of pulses is given in in
the DIAM. MENU. Max 80 Hz.
X1.5 Web Pulse
Pulses from the web each xx mm. The amount of mm per
pulse is given in in the DIAM.MENU. Max. 800 Hz.
X1.57 Calculated diameter output
0-10V DC output corresponding to the diameter calculated in
the controller.
R1 R2 R3 R4 R5 R6
DO 1-4
DI 1-8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
L N PE
TENSION 45 %
Type : X/D-3000
Serial no : 960 034
Voltage : 115V/230V AC
Current : 160mA/80mA
L N PE
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
1 2 3 4 5 6 7 8 9 10
30 31 32 33 34 35 36 37 38 39
0VDC
MANUAL
TENSION OFF
+24V
INERTIA(MAIN START)
+24V
0VDC
DO3 DO4
0VDC
SPLICE
HIGH CALIBRATION
+24V
WEB PULSE
ROLL PULSE
+24V DC FOR DO
0VDC
DO1 WB DO2
START
Optional Connections - Rewind, Printed Circuit Board Version

8
X1.47 0V DC
Connects to the CCW terminal (1) of the MANUAL
potentiometer. Use 10 k Ωpotentiometer.
X1.48 Manual Input
0 to 10 volt input which corresponds to 0 to maximum output
from the controller when in the manual or soft start modes.
Connects to the wiper (2) of the MANUAL potentiometer.
X1.49 10 V Reference
Reference voltage applied to the CW terminal (3) of the
manual potentiometer. Total max. load 5 mA.
X1.18 0V DC
Connects to the CCW terminal (1) of the AUTO
potentiometer. Use 10 k Ωpotentiometer.
X1.19 Auto Setpoint
0 to 10 volt input which corresponds to 0 to full scale tension
when the controller is in the auto mode. Connects to the
wiper (2) of the AUTO potentiometer.
X1.20 10 V Reference
Reference voltage applied to the CW terminal of the AUTO
potentiometer. Total max. load 5 mA.
X1.50 0V DC
Connects to the CCW terminals (1) of the splice level poten-
tiometer. Use 10 k Ωpotentiometer.
X1.51 Splice Level
Input for external signal is used to set output during splice
mode. A 0 to 10 volt input corresponds to 0 to maximum
output.
X1.52 10 V Reference
Reference voltage applied to the CW terminals (3) of the
splice level potentiometer. Total max. load 5 mA.
X1.24 0V DC
Connects to the CCW terminals (1) of the diameter poten-
tiometer. Use 10 k Ωpotentiometer.
X1.25 Diameter Input
Diameter reference input. Maximum 0 to 10 V with
reference to 0V DC. Signal may be supplied from a
potentiometer, ultrasonic sensor or diameter calculator.
X1.27 10 V Reference
Reference voltage applied to the CW terminals (3) of the
diameter potentiometer. Total max. load 5 mA.
X1.44 0V DC
Common for tension outputs.
X1.45 Tension, 0 to 10 V
0 to 10 volts proportional to 0 to full scale tension.
X1.46 Tension, 0 to 100 µA
0 to 100 µamp output proportional to 0 to full scale tension.
X1.23 Diameter Output
Amplified diameter output, adjusted for the correct span and
the points at which taper begins and ends.
Should be 0 volts at minimum diameter and 10 volts at
maximum. Connects to CW (3) of the taper %
potentiometer.
X1.22 Taper % Input
Adjusted diameter output signal, which allows the operator to
set the desired amount of taper. This input determines how
much the setpoint will be reduced as the roll increases in
diameter. If no taper is required, potentiometer may be set to
zero. Connects to the wiper (2) of the taper % potentiometer.
X1.21 0V DC
Connects to the CCW terminals (1) of the taper %
potentiometer.
R1 R2 R3 R4 R5 R6
DO 1-4
DI 1-8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
L N PE
TENSION 45 %
Type : X/D-3000
Serial no : 960 034
Voltage : 115V /230V AC
Current : 160mA /80mA
L N PE
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
15 16 17 18 19 20 21 22 23
44 45 46 47 48 49 50 51 52
0VDC
0VDC
0VDC
0VDC
0VDC
0VDC
+10V
+10V
+10V
MAN. SETP.
SPLICE SETP.
AUTO SETP.
TAPER SETP.
DIAMETER OUTP. CAL.
TENSION OUT. 0-100 uA
TENSION OUT. 0-10V REG OUT 4-20mA
REG OUT 0-10V

9
Optional Connections - All Applications
X1.58 Input 0-10V for Current Converter
Input for voltage to current converter. Converts 0-10V into 0-
20mA / 4-20mA depending on setup.
X1.29 Output 0-20mA / 4-20mA
Output from voltage to current converter. Converts 0-10V
into 0-20mA / 4-20mA depending on setup.
X1.55 External Gain
Input for external gain reference to the regulator. May be
input from diameter calculator or other source. Not used for
special applications.
X1.54 Summation
Extra summing input to regulator circuit (0-20V DC). Used
in intermediate applications where the tacho signal is put
onto the system. The signal has to be galvanic separated.
Except for intermediate only used for special applications.
X1.26 -10 V Reference
Reference supply for external use. -10V max 5mA.
X1.7 Supply for Digital Output
24V DC supply input for supply of digital outputs. Max
0.4A.
X1.8 0V DC
Common for digital output 1 & 2.
X1.38 Digital Output 1 (Web Break)
Digital output 24V DC max 100mA.
X1.9 Digital Output 2
Digital output 24V DC max 100mA.
X1.37 0V DC
Common for digital output 3 & 4.
X1.39 Digital Output 3
Digital output 24V DC max. 100mA.
X1.10 Digital Output 4
Digital output 24V DC max. 100mA.
0VDC
0VDC
0VDC
0VDC
+10V
-10V
Diameter/trim input +10V
Extra output 4-20mA/0-20mA
Input for extra output 4-20mA/0-20mA
Extra analog output 0-10V
External gain 0-10V
Summation input 0-20V
24 25 26 27 28 29
53 54 55 56 57 58
R1 R2 R3 R4 R5 R6
DO 1-4
DI 1-8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
L N PE
TENSION 45 %
Type : X/D-3000
Seri al no : 960 034
Voltage : 115V/230V AC
Current : 160mA/80mA
L N PE
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

10
3.5 Wiring Diagram
Wiring Diagram for X-3000-ce-RW
X-3000-ce
X10.L
X10.N
X10.PE
X1.12 - 2.5 V
X1.13 +INPUT
X1.14 +2.5 V
a
bc
black
white
red
Supply 115 / 230 V AC
Max. 0.16 / 0.08 A
Load cell no 1
X1.41 +2.5 V
X1.42 -INPUT
X1.43 -2.5 V
abc
black
white
red
Load cell no 2
X1.15 GND
X1.16 CURRENT OUTPUT 0/4 - 20 mA
Motor controller
Start
Main machine
start
Splice Tension off
WIRING DIAGRAM FOR X-3000-ce-R
W
© MONTALVO 1996
X/D-3000 FRONTPLATE
Auto/manual
Tension 0 - I
Optional Lo / Hi
Manual setpoint
Auto setpoint
Taper setpoint
Tension
Output
X1.36 +24 V DC
X1.34 START
X1.6 INERTIA
X1.36 +24 V DC
X1.4 +24 V DC
X1.33 +24 V DC
X1.2 SPLICE
X1.32 TENSION OFF
X1.38 WEB BREAK
X1.37 GND
Web break
X1.4 +24 V DC
X1.7 +24 V DC
input for DO
X1.17 VOLTAGE OUTPUT 0-10 V
Diam eter input
X1.26 -10 V
X1.25 DIAMETER +10V
X1.27 +10 V
X1.36 +24 V DC
X1.36 +24 V DC
X1.37 GND
X1.37 GND
Roll pulse
x pulses / rev.
Web pulse
each xx mm
X1.35 ROLL PULSE
X1.5 WEB PULSE

11
Wiring Diagram for X-3000P-ce-RW
X-3000-ce
X10.L
X10.N
X10.PE
X1.12 - 2.5 V
X1.13 +INPUT
X1.14 +2.5 V
a
bc
black
white
red
Supply 115 / 230 V AC
Max. 0.16 / 0.08 A
Load cell no 1
X1.41 +2.5 V
X1.42 -INPUT
X1.43 -2.5 V
abc
black
white
red
Load cell no 2
X1.15 GND
X1.16 CURRENT OUTPUT 0/4 - 20 mA
Motor controller
Start Splice Tension off
WIRING DIAGRAM FOR X-3000P-ce-RW
© MONTALVO 1996
X1.36 +24 V DC
X1.34 START
X1.36 +24 V DC
X1.4 +24 V DC
X1.33 +24 V DC
X1.2 SPLICE
X1.32 TENSION OFF
X1.38 WEB BREAK
X1.37 GND
Web break
X1.4 +24 V DC
X1.7 +24 V DC
input for DO
X1.17 VOLTAGE OUTPUT 0-10 V
Diameter input
X1.26 -10 V
X1.25 DIAMETER +10V
X1.27 +10 V
Taper setpoint
X1.23 DIAMETER OUT
X1.22 TAPER SETPOINT
X1.21 0 V DC
Auto setpoint
X1.18 0V DC
X1.19 AUTO SETPOINT
X1.20 +10 V
Manual setpoint
X1.47 0V DC
X1.48 MANUAL SETPOINT
X1.49 +10 V
Splice setpoint
X1.50 0V DC
X1.51 SPLICE SETPOINT
X1.52 +10 V
X1.44 0V DC
X1.46 TENSION OUTPUT
0-100 uA
10 k ohm
10 k ohm10 k ohm 10 k ohm 10 k ohm
Main machine
start
X 1.6 IN E R TIA
X1.36 +24 V DC
X1.36 +24 V DC
X1.37 GND
X1.37 GND
Roll pulse
x pulses / rev.
Web pulse
each xx mm
X1.35 ROLL PULSE
X1.5 WEB PULSE

12
3.6 Operating the Controller Menu
The controller has four pushbuttons to operate the controller
Return
Enter
Up
Down
Up ↑- scrolls up in menu or is increasing the value.
Down ↓- scrolls down in menu or is decreasing the value.
Return ←- goes one step back in menu level.
Enter ↵- enters a submenu or a value.
By using the Up or Down, the menu line will change to the
next / previous line in the menu system.
Pressing Enter in a menu line, will cause two different
things, depending on if there is a submenu to the line or not.
If there is a submenu, it will go into this submenu.
If there is no submenu and the parameter shown in the line is
changeable, the curser will show up on the last character in
the display. Now the value of the parameter can be changed
with the Up or Down. On all parameters there is an upper
limit and a lower limit.
When a number has been changed, the value can be entered
automatically when the parameter has AUTO ENTER (AE),
and if not, then the Enter (E) key has to be pressed. The
curser will then disappear.
With Return it is possible to go one step back in the menu.
The values all have an upper and a lower limit.
MENU TREE Diagnostic
The diagnostic menu shows the different analog inputs to the operator.
Main menu Submenu Description Enter
DIAGNOSTIC Main menu No
VERSION Software version No
TENSION Analog input no. 2, tension -110% to 110 % No
DANCER Analog input no. 2, dancer pos -110% to 110% No
SETPOINT Analog input no. 1, setpoint -110 to 110 % No
OUTPUT Analog input no. 8, output -110 to 110 % No
I-LEVEL Analog input no. 3, integrator -110% to 110% No
MANUAL Analog input no. 4, manual lev. -110% to 110% No
SPLICE Analog input no. 5, splice lev. -110% to 110% No
SUMMATION Analog input no. 7, summing inp 0-110% No
GAIN Potentiometer level 0-63 steps No
RATIO Potentiometer level 0-63 steps No
DIAMETER Diameter 0-100% No
MENU TREE Password
Main menu Submenu Description Enter
PASSWORD Given in password
To enter into SETUP menu use password 5.
To enter into ENGINEERING and SETUP menu use
password 15.
E
MENU TREE Engineering
Main menu Submenu 1 Submenu 2 Description Enter
ENGINEERING Main menu No
PID MENU No
P LEVEL Potentiometer level 0-63 AE
D LEVEL Potentiometer level 0-63 AE

13
DI MENU No
DI 1 Input on terminal 31 No
DI 2 Input on terminal 2 No
DI 3 Input on terminal 32 No
DI 4 Input on terminal 3 No
DI 5 Input on terminal 34 No
DI 6 Input on terminal 5 No
DI 7 Input on terminal 35 No
DI 8 Input on terminal 6 No
DO MENU No
DO 1 Output on terminal 38 E
DO 2 Output on terminal 9 E
DO 3 Output on terminal 39 E
DO 4 Output on terminal 10 E
AUTO/MAN Internal output E
2. CAL Internal output E
x1/x10 Internal output E
0/4 mA Internal output E
AI MENU No
AI1 Setpoint total No
AI 2 Process value No
AI 3 Inertia level No
AI 4 Normally manual setpoint No
AI 5 Normally splice setpoint No
AI 6 Extra cal. input No
AI 7 Summing input No
AI 8 Analog output level No
AO MENU No
AO 1 Remote setpoint output AE
AO 2 Internal I level setpoint output AE
AO 3 Internal summing output AE
AO 4 Extra analog output AE
COM MENU
REM. SETP. Given over RS485 No
REM MAN. Given over RS485 No
REM SPLICE Given over RS485 No
ADJUST No
AI 1 ZERO Adjusting 0 point on AI 1 AE
AI 2 ZERO Adjusting 0 point on AI 2 AE
AI 3 ZERO Adjusting 0 point on AI 3 AE
AI 4 ZERO Adjusting 0 point on AI 4 AE
AI 5 ZERO Adjusting 0 point on AI 5 AE
AI 6 ZERO Adjusting 0 point on AI 6 AE
AI 7 ZERO Adjusting 0 point on AI 7 AE
AI 8 ZERO Adjusting 0 point on AI 8 AE
AO 1 ZERO Adjusting 0 point on AO 1 AE
AO 2 ZERO Adjusting 0 point on AO 2 AE
AO 3 ZERO Adjusting 0 point on AO 3 AE
AO 4 ZERO Adjusting 0 point on AO 4 AE
MENU TREE Status Menu
Main menu Submenu Description Enter
STATUS MNU Main menu No
INERTIA Shows the level for inertia No
SPLICE Shows the timer for splice No

14
RUN MODE Shows the run mode No
3.7 Menu Tree Survey
Please notice that not all the menus are shown all the time. If the menu is not relevant for the mode or the password is not
correct, it is not shown.
DIAGNOSTIC
VERSION
TENSION
DANCER
SETPOINT
OUTPUT
I-LEVEL
MANUAL
SPLICE
SUMMATION
GAIN
RATIO
DIAMETER
ENGINEER (behind password 15)
PID MENU
P LEVEL
D LEVEL
DI MENU
DI 1
DI 2
DI 3
DI 4
DI 5
DI 6
DI 7
DI 8
DO MENU
DO 1
DO 2
DO 3
DO 4
AUTO/MAN
2. CAL
X1 / X10
0/4 mA
AI MENU
AI 1
AI 2
AI 3
AI 4
AI 5
AI 6
AI 7
AI 8
AO MENU
AO 1
AO 2
AO 3
AO 4
COM MENU
REM. SETP
REM MAN
REM SPLICE
ADJUST
AI1 ZERO
AI2 ZERO
AI3 ZERO
AI4 ZERO
AI5 ZERO
AI6 ZERO
AI7 ZERO
AI8 ZERO
AO1 ZERO
AO2 ZERO
AO2 ZERO
AO2 ZERO
STATUS
SOFTSTART
ANTICOAST
SPLICE
INERTIA
RUN MODE
PASSWORD
SETUP (behind password 5 OR 15)
MODE MENU
RUN MODE
AMPLIFIER
0/4mA
DANCER
LANGUAGE
GAIN
RATIO
P LEVEL
D LEVEL
SOFTS MENU
START OUT
SOFT LEV
SOFT TIME
ANTI MENU
INERT.LEV.
INERT.MIN.
INERT MENU
STA.FRICT.
DYN.FRICT.
SPLCE MENU
SPLICE SRC
SPLICE DEL
SPLICE LEV
SPLICE TME
WEBBR MENU
WEBBR LEV
WEBBR TIME
RANGE EXP
RE LEV -1
RE LEV +1
RANGE TIME
VALVE NO.
START NO.
N MENU
REGULATOR
MIN REG.
MAX REG.
STOP LEVEL
N=0 LEVEL
STOP DELAY
DOUBLE MENU
PRESS FAC
REG. MAX
P LEVEL
I LEVEL
MIN TENSION
DIAM.MENU
DIAM.SRC
P/REV ROLL
MM/PULS
DIAMETER
DIAM.FAC.
MIN DIAM.
MAX DIAM
NO FOR CAL.

15
3.8 Load Cell Rewind - X RW
In this mode there are the following features:
• Start regulation
• Inertia
• Web break
• Splice
The digital signals to connect are the following:
• X1.34 DI5 - Start signal. Used to put the controller into
regulating mode. The input has to be low when the
machine is in stop, and go high when the machine starts.
• X1.6 DI8 - Run signal. Used to put the controller into
inertia mode. In inertia the output is raised when the input
goes high. The inertia fades out.
• X1.2 DI2 - Splice signal. Used to put the controller into
splice mode. The signal is edgetrigged and all the timing
is done by the controller.
• X1.38 DO1 - Web break signal. Goes high when a web
break is taking action.
MENU TREE Setup Menu in Load Cell Rewind Mode
Main menu Submenu 1 Submenu 2 Description Enter
SETUP MENU Main menu No
MODE MENU No
RUN MODE Load cell rewind, X RW E
AMPLIFIER x1 or x10 preamplifier E
0 / 4 mA output 0-20mA or 4-20mA E
LANGUAGE English, deutsch, français, Spanish,
dansk
AE
GAIN System gain 0 - 63 AE
RATIO System ratio 0 - 63 AE
INERT MENU Submenu for inertia. It is possible to
enter this menu to change
parameters.
No
SPLCE MENU Submenu for splice. It is possible to
enter this menu to change
parameters.
No
WEBBR MENU Submenu for web break. It is
possible to enter this menu to change
parameters.
No
DIAM MENU Submenu for calculation of diameter No

16
3.9 Setup Functions
MENU TREE Setup Menu Function Inertia
Main menu Submenu 1 Submenu 2 Description Enter
INERT MENU For rewind applications No
STA.FRICT. Static friction compensation. When
the roll is stopped, the static friction
is raised until it starts to move
slowly.
0.0-20.0 %
E
DYN.FRICT. Dynamic friction compensation. The
dynamic friction is raised until the
tension stays stable during start of
the main machine.
E
MENU TREE Setup Menu Function Splice
Main menu Submenu 1 Submenu 2 Description Enter
SPLCE MENU For unwind and rewind applications No
SPLICE SRC Splice source
Analog input, INPUT
Internal, LOCAL
Remote, REMOTE
E
SPLICE DEL Delay before splice
0.0 to 1.0 sec.
E
SPLICE LEV Local splice level 0 to100 % E
SPLICE TME Splice time 0.1 to 5.0 sec.
During the splice time the output is
held at splice level and there is no
regulation of tension.
E
MENU TREE Setup Menu Function Web Break
Main menu Submenu 1 Submenu 2 Description Enter
WEBBR MENU All applications No
WEBBR LEV. Web break level 0-20 % E
WEBBR TIME Web break time 0.1 to 10.0 sec. E

17
MENU TREE Setup Menu Function Diameter Calculator
Main menu Submenu 1 Submenu 2 Description Enter
DIAM MENU For unwind and rewind applications No
DIAM.SRC Diameter source:
INTERN is calculated from output /
tension
PULS is calculated from pulses on
the brake and on the main machine.
ANALOG is taken from the analog
input on pin X1.22
E
P/REV ROLL If PULS is chosen, the no. of pulses
per revolution on the roll has to be
given. 1 to 200. Max 80 Hz
E
MM/P MAC If PULS is chosen, the mm between
the pulses on the main machine have
to be given. 1-1000 mm.
Max 800 Hz
E
D FACTOR The D FACTOR is a correction
factor for the calculation of diameter
of the roll. The diameter is calculated
from the formula :
D = D FACTOR * Output in %
Tension setpuint
If the actual diameter is bigger than
the calculated, the factor should be
increased. If the actual diameter is
smaller than the calculated, the factor
should be decreased.
E
DIAMETER DIAMETER is the calculated
diameter in %.
No
MIN DIAM. Gives the minimum diameter in % or
in mm if PULS is chosen
E
MAX DIAM. Gives the maximum diameter in %
or in mm if PULS is chosen
E
NO FOR CAL Is the number of pulses from the roll
where the diameter is calculated on.
E
3.10 Mechanical Installation
P version

18
160,0 mm
160,0 mm
10,0 mm
R1 R2 R3 R4 R5 R6
DO 1-4
DI 1-8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
L N PE
TENSION 45 %
Type : X/D-3000
Serial no : 960034
Voltage : 115V/230V AC
Current : 160mA/80mA
147,0 mm
120,0 mm
55,3 mm
X-3000-ce-RW Mechanical Installation
X-3000-ce Dimensions: 330 x 260 x 163 mm

19
20°
45°
18°
18°
Fig 1 Fig 2
Fi
g
3 Fig 4